221105A-01AF-TED SOM-2022 Final Report

DATE:
BMC BRUNEI METHANOL COMPANY

SEPTEMBER OPPORTUNITY OF MAINTENANCE SOM 2022 OCTOBER 2022
TED FINAL REPORT REV 0
SEPTEMBER OPPORTUNITY
OF MAINTENANCE
(SOM-2022)
TED Final Report
October 2022
1
DATE:
Technical Department Final Report
CONTENTS
1. Executive Summary
2. Scope of Work
3. Cost
4. Schedule
5. Quality
6. Contractors
7. Management, Staffing and Organization
8. Summary of Recommendations
9. Lessons Learnt
10. Annexes
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DATE:
1. Executive Summary
This report describes the results of the non-destructive inspection activities

performed during the BMC September Opportunity Maintenance SOM-2022
executed during September-October 2022.
The purpose of the inspection activities during the operational opportunity

was to assess the mechanical integrity of equipment and piping against
recognized international codes, best practices, and company standards,
making recommendations for further improvement of plant load stability and
identifying good practices and lessons learnt for future opportunity
inspections.
Inspection and quality activities comprised equipment and systems of all

disciplines and all areas of the plant coordinated by a QA/QC management
team supported by two specialized local inspection contractors.
The team identified several issues resulting in immediate remedial actions

and recommendations for next STA-2023. Some good practices were also
identified.
Following areas of good performance were noted:
 Accurate daily reporting of findings.

 No overrun.
The most significant issues identified were:
 F-1201 Reformer’s Burners: recurrency of damage in every

opportunity inspection period.
 E-1201-B & E-1202A/B Reformer Convection Module: refractory and
coil support damage recurrency. Hot spots controlled with steam
cooling.
 Transferline and RG Inlet: refractory damage and cracks recurrency.
 B-1620-A/B Suction Stacks: severe internal corrosion.
 T-1611 CW Fans: general severe corrosion.
 Incinerator: refractory damage.
 Flare: badly corroded areas.
 Deployment of a company’s QA/QC organization with clear scope of
work, roles, and responsibilities.
 Implementation of the Equipment Execution Plan -EEP template and
Non-Conformity Report – NCR as the standard documents for
achieving quality assurance and control during execution stage.
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DATE:
 SharePoint site not effectively used.

 Overbudget of 32.70%.
The relevant recommendations are:
Item Equipment Recommended Action Timeline

 Proper tube cleaning
 Tube extubation
 Tube plugging works
1 E-1205
 IRIS inspection STA 2023
 Refractory inspection and
repair works
2 E-1206  TMT UT measurement STA 2023
3 F-1201  Outlet pigtail DPT inspection STA 2023
 Tube Sock replacement/
4 F-1201 STA 2023
repair works
5 F-1201  Burner VT inspection STA 2023
6 F-1201  Finger Duct VT inspection STA 2023
 Outlet System Insulation
7 F-1201 STA 2023
repair/replacement works
 Radiant Box Structural
8 F-1201 STA 2023
corrosion maintenance
9 F-1201  Transfer line VT inspection STA 2023
 EJ#14 and EJ#15
10 F-1201 STA 2023
replacement works
 EJ#9 and EJ#16 VT
11 F-1201 STA 2023
inspection
 Refractory inspection on
Radiant box, Convection
12 F-1201 STA 2023
Module, Transition Duct, and
other area of concern
TMT UT measurement and EX
13 E-1209 STA 2023
overhauling works
14 K-1201T Major maintenance STA 2023
15 K-1201T-TK1 Sampling and LO replacement STA 2023
16 K-1301-P1A Major maintenance STA 2023
17 K-1301-V1 LO Replacement STA 2023
18 K-1301-P1AT Minor maintenance STA 2023
19 V-1402 Bottom cleaning works STA 2025
20 T-1501 Cleaning and inspection STA 2023
21 G-1670T Major maintenance STA 2023
22 G-1670-Z1 Major maintenance STA 2023
23 G-1670-V1 LO Replacement STA 2023
24 U-1620-V4A Resin replacement works STA 2023
25 P-1620A Major maintenance STA 2023
26 P-1620AT Major maintenance STA 2023
27 F1740 Refractory repair works STA 2023
Agitator feed shaft and housing
28 W-1714 STA 2023
replacement works
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29 TK-1901 Bottom plate repair works STA 2025
30 G-1670 General maintenance works STA 2023
31 LTR101 to 104 TR General maintenance works STA 2023
32 MTR-010A/B-TR General maintenance works STA 2023
33 HSWY-100A/B General maintenance works STA 2023
34 SC-100A/B General maintenance works STA 2023
35 BC-1 240VDC General maintenance works STA 2023
37 LMCC-101 to 106 General maintenance works STA 2023
38 TDG General maintenance works STA 2023
39 Probe Maintenance Calibration works STA 2023
40 FT-18001 Direct replacement works STA 2023
Additional O2 Analyzer
41 QT-1207-2 STA 2023
installation
UT Thickness Measurement
according to RBI Plan
Data from SOM 2022 will be
analyzed according to nominal
thickness, corrosion rates and
remaining life estimations, for
According to RBI
42 delivering recommendations
Plan STA 2023
and update/ confirm RBI
program schedule.
Outstanding from SOM 2022 that
were unable to be performed
of UT measurement to defer
for STA execution
The QA/QC management team express their commitment to address the

issues identified and invite Operation and Maintenance departments to
collaborate in the investigation of root causes as a preparation for next STA
planned for 2023.
2. Scope of Work
2.1 Planning and Pre-SOM Stages.
Scope of technical department activities was selected through a risk

assessment performed for maintenance and inspection works before SOM-
2022, considering equipment condition, mechanical integrity, and safety
case standard specifications.
Timeline was selected based on non-availability of natural gas from the

supplier during the period:
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DATE:
Duration
Activity Start Date End Date
s (Days)
Plant Ramp Down/ Making Safe 18th September
15th September 2022 04
Condition 2022
Engineering Days
19th September 2022 02nd October 2022 14
Plant Start-up Operations

03rd October 2022 09th October 2022 07
Technical department was requested to be responsible of the following

inspection (NDT) and QA/QC activities.
 Static equipment external and internal visual inspections during pre-

and post-cleaning.
 Static equipment and critical piping RBI (Risk Based Inspection)
ultrasonic wall thickness measurement.
 Filters external and internal visual inspections during pre- and post-
cleaning.
 Pressure relief valves supervision, coordination, management, and
provision of quality control roles during replacement, testing and
overhauling works at appointed workshop.
 Dye penetrant testing of welding joints for inspection and/or
installation and/or repair works.
 Rotating equipment parts inspection through dye penetrant and
ultrasonic testing.
 Heat exchanger tubes RVT, IRIS, ECT and/or RFET inspections.
 QA/QC in following general activities:
o Verification of spare parts
o Pre-scaffolding erection
o NDT inspections and Maintenance activities as per SOM
schedule
o Seal leak testing (control valves and PSV)
o Box-up
o Tolerance measurement acceptance
o Control loop testing
o Interlock testing
o Completion certificates
o PSSR
During this stage TED supported:
 L4 schedule update for inspection activities.

 Delivery of organization chart for QA/QC management.
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DATE:
 Assignment of QA/QC roles and responsibilities for TED/MTD staff.

 Delivery of EQUIPMENT EXECUTION PLAN (EEP) for each
discipline. EEP is a guideline for each responsible to follow for
QA/QC auditing during execution of maintenance and/or inspection
activities.
Two contractors were selected to support BMC TED Staff during STA-
2021R:
 NDT Services: Industrial Reliability Services, IRS

 QA/QC Services: PTAS
Mobilization of contractors started before September 15 th, 2022, for

temporary facilities installation (IRS) and planning purposes.
2.2 STA Stage.
2.2.1 Process Engineering.
No activity related to process engineering were planned or executed in

this SOM opportunity.
2.2.2 Mechanical Static & Piping.
Static Equipment and Piping.
Tag Scope: Maintenance & Inspection Description Mechanical Static

& Piping
V-1101 NG Booster Suction Drum
Internal visual inspection of vessel interior including demister unit
prior to cleaning
VISUAL after cleaning
prior to final reinstatement of vessel
DPT PT inspection on both circumferential and longitudinal weld seam
lines at both top and bottom of vessel interior after cleaning
Finding VT Vessel interior are generally clean state, with minor flow deposit to
be noted along the inside wall and at bottom of vessel. Demister unit
itself observed of mesh flaking along with light layer of particle
deposit from process fluid flow.
Recommendations Carried out vessel internal cleaning work. The demister unit itself
was replaced with spare set as per instruction.
Finding DPT PT inspection performed for both longitudinal (A-01 & A-02) and
circumferential (B-01 & B-02) weld seam lines observed of no
significant findings be made.
Recommendations To perform PT inspection in next overhauling cycle.
E-1205 Waste Heat Boiler
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& Piping
Internal visual inspection on both RG inlet and outlet side prior to
cleaning
VISUAL
Internal visual inspection on both RG inlet and outlet side after
cleaning and prior to manhole closure
REFRACTORY Refractory inspection/ repair/ cleaning/ closing
PT inspection for 8nos plugged weld line of outlet tube sheet side,
DPT including additional 3 tube weld line suspected with potential of
leakage
Tube internal inspection on cleanliness and condition after wire
RVT
brush cleaning (for 782 tubes)
Tube inspection on wellbeing and soundness condition after RVT
RFET
inspection (792 tubes)
Tube inspection on wellbeing and soundness condition after RFET
IRIS
inspection (optional and to be based on selected tubes)
Pre-cleaning inspection observed of damaged and dropped down
refractory from shell wall, blockage of heat shield/ inlet ferrule holes
by some of the broken refractory pieces at the inlet side.
Finding VT On the outlet side, mainly layer of deposit over the surface of the
tube sheet, indication of flow level-stained marking along bottom of
vessel, and accumulation of refractory dust at bottom of outlet tube
sheet.
 Spalling observed at overhead section of the Cone leading
from TL
 Separation of refractory section at north side of the Cone
leading from TL
 Extensive cracking observed at north side
Finding REFRACTORY
 Surface shearing of refractory section noted at north side
 Lining lifted and loosened at north upper side of the joint
 Cracking showing shearing of the refractory and indicating
the top surface overlapping the lining underneath
 Damaged to refractory lining around the south manhole area
 Removal of badly cracked and spalled area covering mostly
within the hot layer till exposure of vee anchors
 No anchor repair relate works carried out in this SOM
 Reinstate hot face layer using Curon 180T sp GM dense
castable by gunning
 Area surrounding the south manhole was replaced of hot
surface layer like above approach
Recommendations  Other area with minor surface loss was cleared and repaired
using Thermbond Formula 18R
 Temporary patching up of cracked areas using Thermbond
18R/18W made
 Note: For long term, recommend that the entire hot face
layer of the RG inlet to be replaced, along with provision for
repair to cold layer and replacement/ addition of more
anchors.
 PT inspection performed for the 8 welded plug area, and
Finding DPT additional 3 non plugged tube to tube sheet weld line, and no
significant finding on the PT area be made.
Recommendations  To perform full face PT inspection on outlet tube sheet in
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& Piping
next opportunity
Tube internal RVT inspected and observed of acceptable interior
tube cleanliness condition for those tubes that has been wire
brushed.
Finding RVT  While majority of the tubes that do not underwent on wire
brushed cleaning (due to brush unit damaged), observed of
surface deposit along the length, along with indication of
built-up scaling for the said tubes.
 RVT carried out for 792 tubes result not favorable for most of
the tube interior condition. Recommend for proper tube
Recommendations interior wire brush cleaning be made in next opportunity, for
proper assessment of tube condition be made with great
consistency and accuracy.
 Inspection conducted for 792 tubes and found all the tube
Finding RFET
having wall loss < 20%
 Tube inspection result are of acceptable. However, it is
Recommendations recommended for same inspection to be performed in next
opportunity along with proper cleaning be made.
 Inspection conducted for 120 tubes at opportunity and for
Finding IRIS
selected tubes. Maximum wall loss observed to be at 18%.
 Tube analysis made based on maximum wall loss observed
such remaining life to be of 4.5 years prior further loss of
thickness and potential tube failure arise. It is recommended
Recommendations
to carry out proper assessment in next opportunity within this
4 years range, and to prepare tube plugging activity in
conjunction to such opportunity of assessment.

& Piping
F-1201 Steam Reformer – Tube Inspection (DR. FOERSTER GROUP)
Surface scanning for existing Reformer catalyst tube using MANTIS
technology (for 792 tubes)
Tube Scanning
Sample existing catalyst tube scanning using LEO SCAN technology
(for 46 selected tubes)
All tubes are within the acceptance criteria of expansion and creep
damage, with one tube (F-13) having a diametrical expansion of
Finding MANTIS
0.3% among others. Overall tubes are within the operational
acceptance.
All sampled tubes observed to be acceptable, except for tube B-33
Finding LEO SCAN having a small indication and tube H-01 observed of unusual weld at
3rd weld joint line.
Small indication of tube B-33 are of minor and not a cause of
concern. Whereas unusual weld indication for H-01 will probably
Recommendations require further assessment be made in determining on the unusual
cause. Overall, all sampled tubes are adequate for continual in use
till next scheduled turnaround.
F-1201 Steam Reformer – Tube Metallurgical Testing (MHI R&D)
Tube Sump Test Surface grinding of selected shiny tubes for pre-defined top and
bottom section location of such selected tubes and carrying out of
surface microstructural analysis in determining on such
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& Piping
microstructural grain arrangement and condition for determination of
remaining tube life.
Total of 29 selected tubes made for R&D to perform the sump test
analysis, and conclude on the following:
 17nos tubes having estimated remaining life of 4 years
Finding Sump test  6nos tubes having estimated remaining life of 5 years
 1no tube having estimated remaining life of 7 years
 5nos tubes having estimated remaining life of > 10 years
Estimated remaining life is about 5 years at minimum
Final decision will be made once receive and reviewing on both the
Recommendations
final report from DR. FOERSTER GROUP and MHI R&D.
F-1201 Steam Reformer – Tube Sock Replacement/ Repair Works
Inspection on tube sock in identifying on location of sock
VISUAL deterioration and require replacement and repair work be carrying
out.
Identification on such sock deterioration made, and mapping
Finding VT
provided.
Carry out tube sock replacement and repair work as planned.
Recommendations Recommend for further rectification in next scheduled turnaround
opportunity.
F-1201 Steam Reformer – Hanger System
Inspection on outlet system spring hanger condition for functionality
VISUAL
check and adjustment
Most of spring hanger are in operable condition. Particular attention
Finding VT made for spring hanger system along HC-7 length and for A-02
spring hanger, where observed of spring hanger being stuck.
Attempted adjustment made however, the spring mechanism
observed to be fixed and the turnbuckle was unable to move.
Recommendations
Recommend for possible replacement work of the affected spring
hanger system in next scheduled turn around.
Steam Reformer – Expansion joint (EJ#5, EJ#7E/W, EJ#9,
F-1201
EJ#10E/W, EJ#12E/W, EJ#13, EJ#14, EJ#15, EJ#16E/W)
Perform inspection on the identified expansion joint installation for
VISUAL potential deterioration that may anticipate for repair patching and/or
replacement works
Finding VT The findings are as follow:
 EJ#5 observed water stagnation at bottom, along with belt
punctured holes at both top and bottom section.
 EJ#7E observed of belt thinning and fading, along with
punctured holes at top section
 EJ#7W observed of belt thinning and fading, with existing
splice joint opened
 EJ#9 no inspection performed due to unsafe expired
scaffolding
 EJ#10E observed of splicing joint opened at top section
 EJ#10W observed of previously repaired splice joint (April
2022) detached and opened
 EJ#12E inspected and no finding
 EJ#12W inspected and no finding
 EJ#13 total 13nos inspected and #13-4 observed splice joint
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& Piping
opened at top section, whereas #13-5 observed one missing
bolt at top section
 EJ#14 inspected and identified location for replacement and
repair made
 EJ#15 inspected and identified location for replacement and
repair made
 EJ#16E no inspection due to no scaffolding and time
constraint matter
 EJ#1W no inspection due to no scaffolding and time
constraint matter
 EJ#5 no action taken due to no instruction/
miscommunication
 EJ#7E carried out patching work for punctured hole area
only
 EJ#7W carried out splice kit ironing patch up work
 EJ#9 no action being planned due to no finding
 EJ#10E carried out splice kit ironing patch up work
 EJ#10W carried out splice kit ironing patch up work
Recommendations
 EJ#13 on #13-4 carried out splice kit ironing patch up work,
whereas #13-5 no action in having the missing bolt be
replaced made.
 EJ#14 belt replacement made, however, 1 no. not done due
to time constraint
 EJ#15 belt repair and replacement carried out, however,
45nos are not done due to time constraint
 EJ#16 for both side no action be planned.
F-1201 Steam Reformer – Burner Inspection
 Inspection on critically listed burner (total 37nos) for potential
VISUAL
crown assemblies damage and condition.
Inspection managed to be carrying out for those burners having
scaffolding access point, with majority of the burner unable to be
Finding VT inspect in this SOM.
 Out from accessible inspection, 5nos. burner observed with
damaged to the crown assemblies.
 Carried out crown assembly replacement works for 4 of
5nos. identified burner. Remaining burner not replaced of
Recommendations
crown assembly due to no scaffolding access. To be replace
in next scheduled turnaround.
F-1201 Steam Reformer - Finger Duct Inspection
 Inspection on surface of finger duct louver joint and on
VISUAL
bearing housing components
FUNCTION CHECK  Damper louver movement test
 No significant finding on finger duct louver joint and bearing
Finding VT
housing be noted.
 Movement is adequate for operational performance. Top up
Finding Function Test
greasing on each bearing housing made.
 To consider for opening and access onto each of the finger
Recommendations duct internal structure for condition check in next scheduled
turnaround.
F-1201 Steam Reformer – Inlet Header Inspection
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& Piping
 Internal of inlet pigtail and along the pigtail length till
reaching the Inlet Header locate at top of Reformer
RVT penthouse for assessing on both pigtail and header internal
condition. Inspection to be made through blinded point of
inlet pigtail/ tube A1, A2, N1 and N2
 RVT probe managed to reached 4 th of 6th pipe elbow location
for all 4 tubes and restricted of further entry due to the
Finding RVT bending effect from all elbow’s joint location. Mainly debris
and process deposit to be noted at where the probe stopped.
No access to header portion able to be made.
 To consider for better header interior condition check
Recommendations approach subject to further internal discussion based on the
result obtained.
F-1201 Steam Reformer – Hot Collector End Cap and Sleeve Joint
Inspection [HC-3,4,5,6,7 for North side, HC-1,2,3,4,5,6,7 for South
side]
 Inspection on the exposed cap and sleeve joint surface of
VISUAL
Hot Collector
DPT  PT inspection on cap surface and on sleeve weld joint
PAUT  Weld subsurface defect detection
 No detection of surface crack or other abnormalities to be
Finding VT
made
 Small indication of 0.5mm pit-like on base metal detected for
Finding DPT
HC-6 north side. Other HC location no significant findings
 No indication of significant defect to be made for all area,
Finding PAUT
including on the small indication location.
 To perform similar inspection for 100% of HC in next
Recommendations
scheduled turnaround
F-1201 Steam Reformer – Outlet Pigtail Weld-o-let Inspection
 Inspection on surface of exposed weld-o-let joints for 110
VISUAL
joint locations
DPT  PT inspection on weld-o-let joints for 110 joint locations
 No significant finding on those accessible weld-o-let location.
Finding VT Around 23 locations unable to conduct such inspection due
to obstruction by incomplete insulation removal works.
 No significant finding on weld-o-let weld defect made.
Finding DPT Around 23 locations unable to conduct such inspection due
to obstruction by incomplete insulation removal works.
 To carry out 100% of HC weld-o-let inspection in next
Recommendations
Steam Reformer – Insulation Replacement for Outlet Pigtail and Hot
F-1201
Collector
 Inspection in identifying on area of deteriorated insulation for
VISUAL
replacement works
 Scope cancelled due to delays in scaffolding works and on
Finding VT
time constraint
 To be plan in next scheduled turnaround (pre-survey to be
Recommendation
carried out prior to actual shut down)
F-1201 Steam Reformer – Structural Corrosion Maintenance (Radiant Box)
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& Piping
 Inspection in identifying on the location along radiant
VISUAL external wall for scaffolding erection and corrosion
maintenance works
 Scope cancelled due to delays in scaffolding works and on
Finding VT
time constraint
 To consider for pre-survey with markup location, and to
Recommendations
execute in next scheduled turnaround
F-1201 Steam Reformer – Inspection and Deflection Measurement of Hot
Collector
 Perform distance measurement for clamping zone of each of
DIMENSIONAL the hot collector to determine on deflection against reference
axial line
 Some location where adequate insulation removal work
Finding DIMENSIONAL made carried out of such measurement, and not all location
performed due to delays in insulation removal works.
 Available data to be assessed in determining on actual
Recommendations
movement of such hot collector consideration.
F-1201 Steam Reformer – Transferline inspection
VISUAL  TL internal condition check at pre-cleaning
 TL internal condition check at post-repair/ post-cleaning/ final
reinstatement
REFRACTORY  Refractory inspection/ repair/ cleaning/ closing
 Refractory conditions are adequate, with indication of
Finding VT
damaged occur mostly toward the RG Inlet zone area
 Lining generally in good condition
 Debris found directly below Cone #2
 Lining cracked observed at Cone#5
 Between Cone#7 and RG inlet side, previously repaired
filling area observed to have broken away
Finding REFRACTORY
 Same location but on south side similar deterioration being
observed, with 70% of the area affected
 At 500mm from the RG Inlet, severe cracking of lining to be
noted

 Joints throughout the TL were cleaned and infilled with
Thermbond Formula 18W
 The cracks within the inlet side were cleaned and repaired
Recommendations using Thermbond Formula 18R
 The areas on both side wall beyond inlet of Cone#7 and
toward the thermocouples were cleaned out and repaired
using Thermbond Formula 18R
F-1201 Steam Reformer – Radiant Box Internal Inspection
 Inspection on wall and roof deteriorated module lining
condition reported of fallen off during operation. Also, on
VISUAL reported of tube block module reported of fallen off
 Manhole door module and gap filler to be inspect and
rectified of prior to manhole closure
Finding VT  Detail inspection identified 2 location of roof module whereby
part of module observed to have loosened and dropped off.
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 Along the roof and east wall observed of multiple location
where significant module block gap being noted.
 For the manhole door, considerable hot spots around the
manway doors to be noted. The fibre stemming may be
inadequate, due to ill-fitting doors to the surrounding.
 The surrounding area of each of the identified roof module
were repacked using Durablanket Z fibre blanket installed as
folded seals and installed with sliding plates.
 East wall area where there were gaps, were repacked using
Recommendations Durablanket Z fibre blanket installed as folded seals and
installed with sliding plates
 For the manhole door gap that has been widen, stemming
using Durablanket Z ceramic fibre folded using sliding plates
made in packing on all identified gaps made.
F-1201 Steam Reformer – Transition Duct
 Inspection inside of Transition Duct on refractory condition
REFRACTORY
following the opportunity for opening
 Random cracking observed throughout the surface of the
refractory lining, and within acceptable tolerance
 There are 2 panels in the roof in the West Cell where
dropping has occurred indicating that the anchorage is no
longer effective
 In some area the fibre seals have come loose
Finding REFRACTORY  In the Middle Cell, random cracking along with loose
refractory at the joint observed.
 A section of the roof panel also noted of dropped down
 For the East Cell, random cracking of similar nature
observed
 Same goes for roof panels having dropped down indicating
of anchor failure
 Tunnel joints were repacked
 Re-stemming of tunnel wall made
Recommendations
 Large cracks around panels which have dropped were filled
with Thermbond Formula 18R
V-1201 RG WHB Steam Drum
 Borescope inspection through Riser Nozzle N-10b (8”) and
RVT N-10d (24”) in checking on E-1205 bundle tube exterior
condition
 Inspection through N-10b nozzle observed of minor
corrosion/ fouling of bundle tube exterior
Finding RVT
 Inspection through N-10d nozzle and no significant finding
on bundle tube exterior to be noted
Recommendations  No further action to be require
UT  Routine vessel external shell wall thickness measurement
Finding UT  Measured thickness values are above nominal thickness.
 To provide continual thickness monitoring as per scheduled
Recommendations
intervals
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V-1211 WHB Blow Down Flash Drum
 Inspection on vessel internal after opening
 Inspection of vessel internal after cleaning/ prior
VISUAL reinstatement
 Inspection on existing reducing pipe spool
 Inspection on NEW reducing pipe prior to installation
 Observed of red oxide forming around the vessel shell wall.
Minor debris to be observed at bottom of vessel
 Adequate cleanliness made and acceptance prior allow for
closure
Finding VT
 No indication of surface defects to be noted for the existing
reducing pipe spool both internally and externally
 Inspection made however the NEW pipe spool observed to
be of wrong specification.
Vessel internal condition are acceptable in this inspection.
Recommendations Recommend for next overhauling according to pre-defined intervals
for next opening.
 PT inspection on N-1 nozzle to determine on weld and
surface condition before release for cut out works
DPT  PT inspection on N-1 nozzle after hot work replacement
made
 PT inspection on N-2 nozzle to verify on weld integrity
 PT on N-1 nozzle at pre-repaired not done due to site
miscommunication, resulting in N-1 cut out without final
decision made.
Finding DPT
 Inspection done on both beveling and welding stages, and
no significant findings to be made
 Inspection done and no significant findings be made.
 To conduct similar inspection in verifying on the weld
Recommendations
integrity in next scheduled turnaround interval
 Inspection on weld integrity and surface of nozzle material
for N-1 prior to repair
 Inspection on weld integrity and surface of nozzle material
MPI
N-1 during and after repaired work
 Inspection on weld integrity of N-2 nozzle
 Nozzle point weld seam line inspection inside vessel
 No indication of significant defect finding made for all the
Finding MPI
inspected points
 To perform similar inspection in next scheduled turnaround
Recommendations
intervals
 To perform thickness measurement check for wear plate of
UT
N-1 and N-2 nozzle
 No inspection on wear plate performed, as UT measurement
Finding UT
performed for vessel shell (not part of original scope) instead
 To include wear plate inspection in next scheduled
Recommendations
turnaround interval
RT  Radiographic inspection for N-1 nozzle replacement works
Finding RT  Lack of fusion detected for bottom side weld of N-1 repaired
nozzle for 2 times. 3rd inspection performed and result found
15
DATE:

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acceptable.
 Weld quality in term of welder qualification to be reviewed
Recommendations
prior executing for any hot repair work
V-1223 No.1 NG Saturator
UT  Routine external shell wall thickness measurement
Finding UT  Measured thickness value are above nominal thickness
 To perform continual routine thickness measurement
Recommendations
according to defined intervals
V-1401 SPC Steam Drum
 Vessel internal condition check at time of opening
VISUAL  Vessel internal condition check after cleaning/ prior to
manhole closure
 Vessel internal are adequately cleaned state, and free from
mechanical damages. Instrumentation nozzle point N-11B,
N-11D and N-12D observed of tubing blockage
Finding VT
 Vessel internal are acceptable and reported nozzle blockage
already been dislodged and cleared of blockage by means of
borescope
 To schedule for overhauling and cleaning work for
Recommendations anticipated tubing blockage that may encounter during
operation
V-1402 Methanol Separator
 Inspection on vessel interior on top section including
demister units prior to cleaning
 Inspection on vessel interior on top section after cleaning/
prior to manhole reinstatement
VISUAL
 Inspection of vessel interior on bottom section prior to
cleaning
 Inspection on vessel interior on bottom section after
cleaning/ prior to manhole reinstatement
 Vessel internal were lined with paraffin coating throughout
the vessel. The removed demister unit also noted of paraffin
and deposit on the meshing
 Internal of vessel are adequately cleaned and of acceptance
prior to closure. Area in between shell wall to shroud plate
Finding VT still observed of paraffin layer and not done of cleaning work.
 Inspection performed and observed of paraffin lining along
the wall and bottom, including the perforated plate surface
 Inspection performed and found bottom not adequately
cleaned due to time constraint. No proper cleaning has been
made for bottom section.
 To review and probably consider for a thorough and proper
Recommendations
cleaning of vessel in next scheduled turnaround.
 Inspection on N-1 and N-2 nozzle to shell weld joints
 Inspection on upper and lower demister support ring
DPT  Inspection on weld seam line of nozzle points at bottom
section
 Inspection on perforated plates and bracket weld joints
Finding DPT  Inspection made on N-2 and N-5 nozzle with no significant
16
DATE:

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findings
 Inspection made on demister support ring and no significant
findings
 No inspection performed for nozzle points at bottom section
due to inadequate / no cleaning done
 No inspection made for perforated plate due to inadequate/
no cleaning done
 To plan and carry out inspection for bottom section in next
Recommendations
V-1403 Crude Methanol Let Down Drum
 Inspection on vessel interior on condition after opening/ prior
to cleaning
VISUAL
 Inspection of vessel interior on condition after cleaning/ prior
to reinstatement
 Vessel internal coated with paraffin layer (bottom half side)
Finding VT  Vessel has been cleaned and adequately safe for continual
operation
 To perform vessel cleaning at pre-defined interval for
Recommendations
overhauling
UT  Routine vessel shell external wall measurement
Finding UT  Measured thickness are below the nominal thickness value
 To perform further analysis based on the result obtained and
Recommendations
to conclude on way forward at later stage
 Inspection on longitudinal and circumferential weld seam
MPI
inside vessel
 No indication of significant defects to be noted from the
Finding MPI
inspection
 To continue with the current pre-defined interval for
Recommendations
overhauling in next opportunity
V-1404 Vent Scrubber
 Inspection on removed pipe spool of N-2 prior to cleaning
VISUAL  Inspection on removed pipe spool of N-2 after cleaning
 Inspection on NEW top cover prior to installation
 No significant defects to be noted at time of removal stage.
Gasket seats are adequate.
 Surface are adequately cleaned and acceptable for
Finding VT
reinstatement
 No indication of mechanical damaged nor other defects to be
noted.
Recommendations  Proceed with the reinstatement work as planned.
 PT inspection on removed pipe spool of N-2 flange weld
seam lines after cleaning
 PT inspection on N-2 flange tie in weld seam line of NEW
DPT
top cover
 PT inspection on circumferential weld seam lines prior
reinstating
Finding DPT  No significant finding on defects relates to be observed
 No significant finding on defects relates to be observed
17
DATE:

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 No significant finding on defects relates to be observed
 Proceed with the installation works. Recommend defining
Recommendations the intervals for next scheduled turnaround inspection be
made.
B-1620A-SK1T Boiler A Suction Stack
 Inspection on Stack exterior surface including top roof
section
 Inspection inside of Stack after removal of damper unit,
VISUAL
including damper itself and FD Fan structure
 Inspection inside of Stack including damper itself and FD
Fan structure after repair work/ prior to reinstatement
 Indication of surface paint deterioration, along with spot
corrosion and surface general corrosion condition being
observed
Stack bottom plate observed of ruptured, along with surface internal
corrosion of Stack wall lining and duct condition. FD Fan structure
also noted on surface general corrosion and deteriorated arm bar
pipe support.
 Damper louver also noted of severe corrosion condition.
Finding VT
Surface of Stack was reinstated with new bottom plate and general
corrosion maintenance work performed for the Stack wall lining.
Reinforced plate also welded at the Stack to damper opening base.
For the FD Structure, mainly corrosion maintenance performed, and
new arm bar welded to replace the deteriorated.
 General cleaning and corrosion maintenance work
performed for the corroded damper louver unit as much as
possible,
Recommendations  Performed necessary corrosion maintenance work where
deem applicable in this SOM. Recommend for next
scheduled turnaround to have Stack exterior having
corrosion maintenance work be perform, replacement of
damper unit with better specification. It is recommended to
consider for Stack replacement in the long run.
B-1620A-SK1T Boiler A Suction Stack
section
VISUAL
Finding VT  Indication of surface paint deterioration, along with spot
observed
 Stack bottom plate observed of ruptured, along with surface
internal corrosion of Stack wall lining and duct condition. FD
Fan structure also noted on surface general corrosion and
deteriorated arm bar pipe support.
 Surface of Stack was reinstated with new bottom plate and
general corrosion maintenance work performed for the Stack
18
DATE:

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wall lining. Reinforced plate also welded at the Stack to
damper opening base. For the FD Structure, mainly
corrosion maintenance performed, and new arm bar welded
to replace the deteriorated.
possible,
MPI  Inspection on weld seam line following structural and plate
replacement works
Finding MPI  Inspection performed for plate repaired work around Stack
and FD structure, and no significant finding be made.
Recommendations  Inspection proceeds as planned. Next interval for similar
inspection to be define at later stage.
UT  Routine Stack shell wall thickness measurement
Finding UT  Measured values (at average of 4.475mm) observed to be
below the nominal thickness (5mm)
Recommendations  To consider for possible Stack replacement work in long
term
B-1620B-SK1T Boiler B Suction Stack
section
VISUAL
 Indication of surface paint deterioration, along with spot
observed
 Stack bottom plate observed of ruptured, along with surface
internal corrosion of Stack wall lining and duct condition. FD
Fan structure also noted on surface general corrosion and
deteriorated arm bar pipe support.
Finding VT  Surface of Stack was reinstated with new bottom plate and
general corrosion maintenance work performed for the Stack
wall lining. Reinforced plate also welded at the Stack to
damper opening base. For the FD Structure, mainly
corrosion maintenance performed, and new arm bar welded
to replace the deteriorated.
possible,
19
DATE:

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 Inspection on weld seam line following structural and plate
MPI
replacement works
 Inspection performed for plate repaired work around Stack
Finding MPI
and FD structure, and no significant finding be made.
 Inspection proceeds as planned. Next interval for similar
Recommendations
inspection to be define at later stage.
UT  Routine Stack shell wall thickness measurement
 Measured values (at average of 4.525mm) observed to be
Finding UT
below the nominal thickness (5mm)
 To consider for possible Stack replacement work in long
Recommendations
term
V-1620 Deaerator
 Inspection inside of vessel and around M-1 manhole nozzle
after opening
VISUAL
 Inspection inside of vessel after final cleaning/ prior to
reinstatement
 Internal of vessel are adequate with no significant debris or
deposit to be noted. M-1 nozzle observed of lack of fusion
along weld capping layer of length 15mm.
Finding VT  Internal of vessel are in cleaned condition following post
repaired and general cleaning works performed. Indication
observed around M-1 manhole has been rectified and
adequate for continual in use.
 Repair work by grinding to remove the defects made in this
SOM. Remaining thickness are adequate and well above the
Recommendations nominal thickness range of such nozzle. It is recommended
to define opening interval for next verification of the repaired
area.
 Inspection along the M-1 nozzle circumferential and
DPT
longitudinal weld seam line for verification of weld defects
 Inspection performed and indicated of weld defects at 3
Finding PT locations around the manhole circumferential weld seam
lines.
 Performed grinding off defects followed by repeated
inspection to ensure no crack propagation and eventual
Recommendations elimination of such crack be made. It is further
recommended to define next interval for opening to verify
again on the post repaired condition.
 Inspection in determining on the observed weld defects on
UTG/ UT SCANNING
the actual depth and extend of such defect growth
Finding UTG/ UT  Weld defect with depth of 1.5mm detected.
SCANNING
Recommendations  Surface grinding off for such weld defects carried out
according to the identified defect depth. Nominal thickness of
nozzle being 12mm, with require thickness of 8.33mm. After
repaired work done, remaining thickness was checked and
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DATE:

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observed to be of 10.2mm.
 Routine external shell wall thickness measurement for both
UT
Deaeration and Storage tank
 Measured values are well above the nominal shell wall
Finding UT
thickness
 To continue with routine measurement at pre-defined
Recommendations
intervals
V-1650 Boiler FNG Buffer Drum
 Inspection on vessel internal and removed demister unit
prior to cleaning
VISUAL
 Inspection on vessel internal and demister unit after
cleaning/ prior to reinstatement
 Vessel internal observed of powdery deposit from process
NG. the demister unit also noted of whitish deposit all over
the mesh.
Finding VT  Vessel internal were adequately cleaned in removing of all
deposit presence as much as possible. The demister unit
itself were properly water jet cleaned and reinstated to
useable and acceptance condition. Bolts/nuts for demister
were checked for tightness prior manhole closure.
 Performed internal cleaning of vessel and on demister unit.
Recommendations Recommend for next overhauling to check on deposit
content in next scheduled turnaround.
 PT inspection for all longitudinal and circumferential weld
DPT seam lines, including all nozzle points, structural weld lines
and demister support rings
 Inspection performed on all weld lines and no significant
Finding DPT
findings be noted.
 The inspection was performed according to inspection plan
Recommendations and recommended for similar inspection be made at next
scheduled turnaround.
UT  Routine external vessel wall shell thickness measurement
 The measured values are well above the nominal shell
Finding UT
thickness values
 Performed UT measurement as planned. Routine at pre-
Recommendations
defined interval for such measurement shall be maintained.
V-1651 NG Inlet Separator
 Inspection inside of vessel including demister unit after
opening/ prior to cleaning
VISUAL  Inspection inside of vessel including demister unit after
cleaning/ prior to reinstatement
 External vessel surface condition check
Finding VT  Vessel internal observed to have coated with heavy yellow
slimy deposit throughout the internals. Accumulation of such
mixture of powdery and hardened deposit found at bottom of
vessel internal. Deposit observed to harden and form into
fiberglass-like material when mixed with water. Demister unit
itself also indicated of wet slime deposit on the mesh along
with cotton rag material.
21
DATE:

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 Vessel internal are cleaned at adequate condition as much
as possible with most of the deposit being removed
manually. Demister unit itself are also cleaned and with
small quantity of cotton rag material still adhere on the
surface. Removal may be difficult due to meshing gap
condition that limited manual removal be made.
 External surface of vessel observed of stained and algae
growth at top section.
 Proceed with cleaning on both vessel internal and demister
unit using WJ after manual removal of yellow deposit. No
cleaning done for external vessel due to early indication of
such growth and can be perform during normal operation.
Recommendations  Recommend for vessel internal cleaning work to be
performed at pre-defined intervals of next scheduled
turnaround opportunity. Also, to consider on possible
demister unit replacement if similar blockage condition of
rag-like material observed.
 Inspection on vessel longitudinal and circumferential weld
DPT seam lines, weld line of all nozzle points and on demister
support ring condition after cleaning.
 Inspection performed on all weld seam lines and observed of
Finding DPT
no significant findings be made.
Recommendations  Inspection proceeds as per planned with no findings made.
 Measured values are well above the nominal shell wall
Finding UT
thickness
 To continue with routine measurement at pre-defined
Recommendations
intervals
V-1652 NG Condensate Drum
Finding UT  Measured values found to be slightly below the nominal shell
wall thickness
Recommendations  To review and assess on current value reading for possible
recommendation and requirement of vessel for next
opportunity of overhauling works

& Piping
F-1740 Incinerator
VISUAL External inspection of Incinerator for deterioration and condition
check
22
DATE:
Internal inspection of Incinerator internal after opening/ prior to repair

works
Internal inspection of Incinerator internal after repaired work/ prior to
reinstatement
External inspection observed of surface paint deterioration and
corrosion condition. In some instances, several flanges observed of
loose and missing bolting. Civil foundation observed of cracked at
north side. Corrosion on structure including damper wind box unit
also noted.
Internal inspection observed of broken refractory pieces at bottom
side. Along the wall castable observed at 2 locations of holes
through such castable brick material. At top section one refractory
Finding VT
cast brick noted of damaged near to the choke ring section.
Post repaired and cleaning inspection performed inside of Incinerator
and found to have adequately cleaned of debris, particularly at
bottom section. Area of 2 location reported of holes were not carried
out of any repaired works, probably the current condition deemed
sufficient for continual operation and not of major concern. Area at
top where refractory brick reported of damaged has been carried out
of repair works.
External of Incinerator carried out of flange reinstatement works.
Blasting and painting work also performed for the Incinerator unit as
overall. Damper wind box corrosion maintenance and other
replacement work also executed in this opportunity. Recommend for
continual monitoring during online on the surface condition.
Recommendations Internal of vessel carried out of necessary refractory relate repair
work and completed. Balance for reported holes to be followed up in
next opportunity. Recommend for opening of the Incinerator for a
follow up inspection on post repaired condition and also on balance
items, subject to pre-defined interval for next scheduled turnaround
opportunity.
REFRACTORY Inspection of refractory condition inside of Incinerator
 Burner Quarl tile has a broken edge, but no effect to burner
operation
 Buildup of deposit on the viewing pot along the castable
brick of shell side
 Minor cracking observed at Choke Ring
Finding REFRACTORY  One of the brick has snapped and become loose and
dropped by 30mm, however, it appear to have retain in place
 Area above the choke ring appear to have a loose deposit
layer of combustion waste that may affect performance on
the refractory over time

& Piping
 At area above the choke ring and into the transition cone
and lower stack, the surface of the refractory has eroded
over time and the tips of the anchors all around the
circumference are exposed indicating that the lining has
been reduced by 15mm.
23
DATE:
Recommendations Rectification works were executed for the choke ring section only,
whereby the debris at the back of the dislodged brick was removed,
and the internal sides prepared with Thermbond Formula 18W. The
brick was gently eased back into position and propped for support
over a period of 12 hours to allow it to set. The prop was removed,
and the cracked surface was coated with Thermbond Formula 18W
as a protective coating. Other area remains as it is, as it pose no
concern for Incinerator operation. It is also recommended to have the
choke ring block replace of the brick due to currently observed of
loose condition. Area above the choke ring to be rectified in next
opportunity where possible.
DPT PT inspection for any anchor weld repair work inside of Incinerator
Finding DPT No removal of existing refractory lining be made; hence no
inspection being performed.
Recommendations No plan unless it was pre-defined on the necessity beforehand or
anticipate refractory lining repair work above the choke ring section
be carrying out.
W-1714 Clarifier
Inspection on the clarifier basin condition after cleaning are done
VISUAL
Inspection on the existing feed piping after cleaning are done
Basin is adequately cleaned up and acceptance. Along the basin
wall observed of spot deterioration of concrete condition at multiple
location along with rusty stained patch.
Structural support for both Agitator shaft and housing unit observed
of severe corrosion and deterioration, posing a risk of broken off and
Finding VT
falling off for the housing. Multiple through holes of sizeable condition
resulting from corrosion effect were noted along the housing casing
itself, and on the agitator shaft structure. The Agitator blade unit also
found to have deteriorated, with the blade rubber being worn out and
entirely defeating the sweeping purpose.
Existing feed piping also noted of multiple corrosion effect perforated
through holes at multiple location. This has deemed the pipe being
unusable and serve no purpose in channeling the waste contents
over its designate path. New pipe spool are available for the
replacement.

& Piping
Recommendations Cleaning has been carried out and found to be adequate. Feed
piping with multiple defective holes has been replaced with new
length, with flange joint salvaged back and reuse from existing. Other
area of concerns on Agitator shaft, turnbuckle on sweep mechanism
24
DATE:
and on housing will require some corrective action or possibly

replacement to be made. Support structure for Agitator and housing
found deteriorated require to be repair and replace with new set. Civil
wall of reported spot deterioration requires to be surface preparation
and apply of protective coating to prevent further deterioration over
time.
It is recommended for the necessary action be made in next
available scheduled turnaround event.
UT Routine external shell wall thickness measurement for new feed

piping
Measured values are baseline data for the new feed piping, and to
be record and reference with succeeding measurement value later.
Finding UT
Existing pipe found deteriorated and not required for such
measurement be performed.
To continue with routine measurement at pre-defined intervals in line
Recommendations
to Clarifier maintenance scope
TK-1802A Crude Methanol Tank
Internal inspection of tank condition after opening/prior to cleaning
VISUAL
Internal inspection of tank condition after cleaning done
Finding VT Prior to cleaning, solid accumulation of paraffin balls noted around
the center of the tank, and at south side of tank internal. There is
also presence of layer process deposit throughout the tank bottom.
Some of the nozzle point also noted of deposit inside the nozzle
length.
After cleaning and dry out, presence of process dust deposit can be
noted inside the tank bottom. Repetitive manual sweeping and
vacuum cleaning require to be carrying out to properly clean of tank
internal.
Recommendations Tank internal cleaning proceed as per planned and attempted in
removal of dry process deposit made over multiple times to produce
an adequately cleaned surface for necessary inspection be perform.
It is recommended to include manual vacuuming be include in the
overall tank cleaning operation.
MPI Inspection on tank bottom plate to plate weld joints, on bottom,
annular and sump plate joints, all nozzle weld seam lines and on
plate patching repair weld line where applicable.
Finding MPI Surface affected plates are adequately cleaned of process deposit
and performed of inspection. No indication of significant defect
finding to be made in the inspection for all affected weld areas.
Recommendations Inspection proceeds as planned and recommend for similar
inspection to be performed for every interval of tank overhauling
works.
UT Tank bottom plate thickness measurements
Finding UT Measured values indicate of acceptance and within the criteria of
nominal thickness condition.
MFL Inspection Tank bottom plate scanning for thickness verification, and on defect
depth and material loss determination

& Piping
Finding MFL Bottom plate scanning indicates of general wall loss by < 10% in
volume. No indication of surface plate defect (i.e. pitting and others)
25
DATE:
to be noted at time of such inspection.

Recommendations Bottom plates are adequate with no significant findings made on
corrosion and pitting effect. Anticipated wall loss is of general, with
<10% loss by volume. Tank bottom plate are deemed good and fit for
continual in use. Recommend for another MFL inspection be made in
next overhauling schedule (i.e. 2025).
TK-1803 By Product Tank
Tank internal inspection on condition after opening/ prior to cleaning
VISUAL
Tank internal condition after cleaning done/ prior to reinstatement
No pre-cleaning inspection being performed due to unsafe for
internal entry (high ethanol vapor emission) as per HSE
recommendations.
Finding VT Tank internal after cleaning were inspected and found to be
adequate with acceptable condition. General surface rust condition
to be noted especially along the tank bottom section. No indication of
plate pitting of significant depth to be noted.
Inspection performed as planned, and surface are adequate for
Recommendations
continual in use.
MPI Inspection along the weld seam line between plate (100%)
Finding MPI No detection of weld significant defects to be noted.
As no defects being detected I the inspection, no action plan to be
Recommendations
made.
UT Routine bottom tank plate wall thickness measurement
Bottom plate measured values indicate of below nominal plate
thickness by 7.5%. Sump plate thickness also below of nominal plate
thickness by 3.75%.
Finding UT
Drain piping inside of tank has an average wall thickness lower than
the nominal pipe thickness by 3% value. Such are not detrimental in
affecting on the pipe performance whilst in operation.
Actual thickness value is of acceptance for continual in use.
Thickness analysis require to be performed in determining on
Recommendations optimum condition for in service application and shall be update at
later stage. Interval on tank overhauling to be revisit in
accommodating on bottom plate finding.
TK-1901 Fire Water Tank
VISUAL Internal inspection of tank condition after opening/prior to cleaning
Internal inspection of tank condition after cleaning
Finding VT Internal inspection after opening observed of scale deposit along the
shell wall course plates. Bottom of tank also noted of deposit from
sludge and sand deposit.
Internal of tank after cleaning found to be adequately cleaned of
deposit on both shell wall course and bottom of tank. General rusty
surface pattern to be noted for bottom section of the tank
Recommendations Proceed with tank internal cleaning using water jetting aid with
scaffolding erection in reaching top portion of the tank for cleaning
purpose.

& Piping
UT Measurement of tank bottom plate wall thickness including the
annular, base plate and on the sump area
Finding UT Measured thickness value for bottom plate indicated of below plate
26
DATE:
nominal thickness by 1.25%. whereas for sump plate thickness

below nominal value are by 4.38%. Drain piping observed of
adequate remaining thickness in place.
Thickness measurement proceed as planned. The % loss are not of
Recommendations
major concern, enabling the tank to continue in operation of use.
Inspection of weld seam line between bottom, annular and sump
MPI
plates
Inspection performed on all applicable weld seam line and reported
Finding MPI
of no significant defect finding be made.
Recommendations Proceed for carrying out such inspection according to plan.
MFL Inspection Tank bottom plate scanning for thickness verification, and on defect
depth and material loss determination
Finding MFL Bottom plate scanning indicates of following:
 Bottom plate wall loss up to 22.50%, along with pitted depth
of 1.80mm
 Bottom Annular plate wall loss up to 27.75%, along with
pitted depth of 2.20mm
Recommendations Indication of visible pitting occur around the affected plate region to
be noted.
 Bottom plate wall loss of 1.80mm imply to a remaining
thickness of 6.2mm. Design plate thickness are of 8mm,
having a minimum requirement of 7.5mm be in place.
Current thickness is of 17.33% lower than the require
thickness. It is anticipated that analysis on corrosion rate and
remaining life be made in consideration for early plate
patching work be in place for next available opportunity be
made.
 Annular plate wall loss of 2.20mm imply to remaining
thickness of 5.80mm. Minimum thickness require as per API
are of 6mm (loss by 3.33%). Consideration to be made
similar to base plate evaluation on the necessity for plate
patching or repair work be made in place at next available
opportunity.
K-1202 FDF Suction Hood
VISUAL External and Internal inspection of FDF Suction Hood after hand
over
External and Internal inspection of FDF Suction Hood after repaired
works
Finding VT Observed of contaminated bird mesh with air pollutant, general
corrosion on bird mesh frame structure, corroded weld seam line
inside of hood and along support leg and end plate joint connection
points
Surface removal of corroded region along end plate connection joint
cleaned and apply of painting works. Surface of bird mesh cleaned
and free from contaminant. Touch up on hood bolting also made.
Recommendations Proceed on corrosion maintenance works according to work plan.

& Piping
No removal/ lifting of hood structure to ground level be made. All
works done at installation.
27
DATE:
Recommend conducting another inspection in next scheduled

turnaround opportunity
PNG Piping 16”-PNG-12009-MS1-HC
Inspection on removed elbow joint (2nos)
VISUAL
Inspection on straight pipe length after elbow joint removal
Elbow joints observed to be free from corrosion and deterioration
condition at both internally and externally. Flange gasket area are
Finding VT
adequate with no defects being observed.
Straight piping also performed of inspection and no defect detected.
Proceed with the inspection according to plan and no finding be
Recommendations
made.
RVT Internal inspection on straight pipe length
Finding RVT Minor debris and fouling observed inside of the pipe length
Proceed with RVT inspection and findings made. No action taken as
Recommendations observation are more toward entry and mid-section of the pipe
length.
Inspection on flange weld seam lines of both elbow joint end, and on
DPT
straight pipe length flange weld lines
Finding DPT No indication of surface weld defects being made.
Proceed for the inspection as per planned, and no major finding on
Recommendations
both the elbow joint and straight pipe length be made.
PS-1411A Pump Strainer PS-1411A
VISUAL Inspection and Cleaning
Finding Strainer elements are free from debris, and with minor dirt on the
meshing. The housing itself are adequate with general cleaning be
required.
Recommendations Proceed for cleaning on both strainer housing and element, followed
by reinstatement works
PS-1411B Pump Strainer PS-1411B
meshing. Bottom of element observed of rusty stained pattern The
housing itself are adequate with general cleaning be required.
PS-1503A Pump Strainer PS-1503A
Finding Strainer elements are clogged with black deposit and contaminants.
The housing itself also observed of surface contaminant.

& Piping
PS-1503B Pump Strainer PS-1503B
28
DATE:
Finding Strainer elements are clogged with black deposit and contaminants.
The housing itself also observed of surface contaminant.
PS-B1620A-1 Pump Strainer PS-B1620A-1
Finding Strainer elements are free from deposit clogging. No damaged
observed. Housing itself are observed minor dirt at bottom side.
PS-B1620B-1 Pump Strainer PS-B1620B-1
Finding Strainer elements are free from deposit clogging. No damaged
observed. Housing itself are observed minor dirt at bottom side.
FX-18001 Pump Strainer FX-18001
meshing. The housing itself are adequate with general cleaning be
require.
Tag Scope: Maintenance & Inspection Description UT- Wall

Thickness Measurement
E-1516 Distillation Bottom Cooler
UT Wall thickness measurement for exchanger channel head and shell
Finding UT Measured thickness value are adequate and above the nominal
29
DATE:
design thickness values.

Baseline UT thickness for new exchanger made in this SOM
following installation made in STA 2021R. To proceed with routine
Recommendations
wall thickness measurement at pre-defined intervals (i.e. STA 2
yearly frequency)
PIPING UT CP Line System (80 piping lines)
UT Wall thickness measurement on piping length
Finding UT 80 out of 80 CP system lines were carried out of UT Inspection. Data
to be reviewed.
Recommendations Data will be analyzed according to nominal thickness, corrosion rates
and remaining life estimations, for delivering recommendations and
update/confirm RBI program schedule.
PIPING UT PZ Line System (129 piping lines)
Finding UT 116 out of 129 PZ system lines were carried out of UT Inspection.
Those not carried out were due to no scaffold access and/or pipe
insulation not removed. Data to be reviewed.
update/confirm RBI program schedule. Plan to carry out balance
lines during next shutdown opportunity.
PIPING UT RG Line System (42 piping lines)
Finding UT 32 out of 42 RG system lines were carried out of UT Inspection.
Those not carried out were due to no scaffold access and/or pipe
insulation not removed. Data to be reviewed.
update/confirm RBI program schedule. Plan to carry out balance
lines during next shutdown opportunity.
PIPING UT Boiler A System (17 piping lines)
Finding UT 17 out of 17 Boiler A system lines were carried out of UT Inspection.
Data to be reviewed.
PIPING UT Boiler B System (17 piping lines)
Finding UT 17 out of 17 Boiler A system lines were carried out of UT Inspection.
Data to be reviewed
Corrective Maintenance.
30
DATE:
Scope: Maintenance & Inspection Description

Tag
Corrective Maintenance - Backlog
CM
D/S manual valve of HV-1111 jammed open
COLD WORK
Inspect flange surface and cleaning
VISUAL
Findings No finding made. Valve stem internal part issue
Recommendations Carry out 10"#300 valve replacement
CM
Incinerator air damper issue
COLD WORK
VISUAL To carry out condition check on pin condition
Findings Pin observed corroded and deteriorated
Recommendations Carried out pin replacement
CM
PTR - Wrong gasket specification installation at Process Area
COLD WORK
VISUAL Inspect and verify on existing RJ gasket condition
Findings Wrong specification as pre-identified earlier
Recommendations Carried out flange gasket replacement - 3/4", 1/2"& 1"1500#
CM
PTR - Wrong gasket installation at Compressor area
COLD WORK
VISUAL Inspect and verify on existing RJ gasket condition
Findings Wrong specification as pre-identified earlier
Recommendations Carried out flange gasket replacement - 3/4", 1/2"& 1" & 3”1500#
CM
V-1211 valve passing
COLD WORK
VISUAL To carry out 6"150# valve replacement
Findings No finding made. Valve internal part issue
31
DATE:

Tag
Recommendations Valve replacement carried out
CM
Main 8'' FNG burner header flange leak
COLD WORK
VISUAL To replace 8"butterfly valve
Findings No replacement made due to resource constraint
Recommendations Propose deferment to STA 2023
CM
K-1201T-E1A Lube Oil Leaked
COLD WORK
VISUAL Removal of existing LO valve for verification on condition
Findings No finding be made
Recommendations Replacement of valve carried out
CM
FTW line to vapor seal pot (SP1820B) clogging
HOT WORK
VISUAL Cut and remove affected spool / Install and weld with new piping (1
DPT length) / Touch-up painting
Findings PT: Pipe welding work no significant finding of defects.
Recommendations Replaced.
CM
12"-PTW-11242 line leakage
HOT WORK
VISUAL
Cut and removal/ replacement of 2 length of piping/ Touch up painting
DPT
Findings PT: No indication of significant weld defects for the new line observed
Recommendations Replacement with new pipe length made
CM
K1101 air ejector gland leak
HOT WORK
VISUAL To carry out hot cut out and replacement of manual valve (1”& 1 ½”
DPT both #800)
32
DATE:

Tag
Findings PT: No indication of weld defect to be noted
Recommendations Proceed for valve replacement works
CM
Drain valve passing SM inlet to K-1301-P1AT drains
HOT WORK
VISUAL Carry out removal of insulation/ cut out of existing and replacement
DPT with new drain valves (3/4” of 2nos)
PT: No indication of weld defects for the replaced valves. Existing
Findings
valve found worn out of valve part for the packing area.
CM
Drain valve passing RG line to K-1301LP
HOT WORK
VISUAL
To perform cut out and replace valve - 3/4"(1no.)
DPT
PT: No indication of weld defect for the replaced valve. Removed
Findings
found stuck of stem condition
CM
Drain valve passing u/s of PV-1408-2
HOT WORK
VISUAL
To cut out and replace valve - 3/4"(2nos.)
DPT
PT: No indication of weld defect for the replaced valve. The removed
Findings
valve observed of worn-out internal component
CM
Drain valve passing u/s of XV-1412 to V-1406
HOT WORK
VISUAL Insulation removal, cut out existing valve and replacement with new -
DPT 2" #600(2nos)
Findings valve observed to be stuck open position possibly due to internal part
corroded.
Recommendations Proceed for such valve replacement works
CM
Drain valve passing u/s of XV-1413 to V-1406
HOT WORK
33
DATE:

Tag
DPT 2" #600(2nos)
Findings valve observed to be stuck open position possibly due to internal part
corroded.
CM
Drain valve passing u/s of HV-1402B to SPC
HOT WORK
DPT 3/4"(2nos)
Findings valve observed to be stuck open position possibly due to jammed
stem
CM
Steam trap faulty (chattering sound) near to E1404
HOT WORK
VISUAL Insulation removal, cut out existing trap and replacement with new -
DPT 3/4"(1no)
No replacement made in this opportunity due to no spare valve
Findings
available
Recommendations Propose deferment to STA 2023
CM
Drain passing downstream of S39 (PG-1407) V-1406 to SL Header
HOT WORK
DPT 3/4"(1no)
Findings valve unable to full close possibly due to foreign material affecting
proper seating of valve
Recommendations Proceed for such valve replacement work
CM
HV-1402A/B drain valve passing
HOT WORK
DPT 3/4"(4nos)
PT: No indication of weld defect for the replaced valve. Suspected
Findings
improper seating of existing valves.
34
DATE:

Tag
Recommendations Proceed for valve replacement work
CM
V-1401 blow down valve jammed
HOT WORK
DPT 3/4"(1no)
PT: No indication of weld defect for the replaced valve. Existing valve
Findings
suspected of stem sticking over time
CM
TV1214 drain valve passing
HOT WORK
DPT 1.5" 1500#(2nos.)
PT: No indication of weld defect for the replaced valve. Existing valve
Findings
condition yet to be verify.
CM
Steam trap on SM inlet to F-1740 passing
HOT WORK
VISUAL Insulation removal, cut out existing trap and replacement with new -
DPT 3/4"(1no.)
PT: No indication of weld defect for the replaced steam trap valve.
Findings
Possibly of deteriorated internal part for the removed trap valve.
CM
6''-PZ-15121-MC3-HB piping leakage
HOT WORK
VISUAL
DPT To cut out, remove and install new length
RT
PT and RT indicate of good weld quality with no significant defects be
detected. Existing pipe length subjected to process damaged
Findings
mechanism and deteriorated pipe integrity condition resulting from
damaged mechanism in place.
Recommendations Proceed for pipe replacement according to agreed length.
CM
TK-1610 outlet pinhole leak (18''-FTW-11001-LC1)
HOT WORK
35
DATE:

Tag
VISUAL
To cut out, remove and install new length (short spool)
DPT
PT: No indication of weld defect for the replaced pipe spool length.
Findings Existing pipe observed of biologically induced corrosion effect from
service fluid.
Recommendations Proceed for the pipe length replacement works
CM
V-1509 Inlet 26'' RG line leakage
HOT WORK
VISUAL
To carry out cut out and replacement of tee section
DPT
Scope cancelled due to late delivery of require component for pipe
Findings
modification works(purging use).
Recommendations To be follow up on next scheduled opportunity (STA 2023)
CM
W-1714 feed 8'' line pinhole leaked
HOT WORK
VISUAL
To cut out, remove and install new length
DPT
PT: No indication of weld defect to be made. Existing pipe length
Findings observed of perforated holes of adequate sizing along the length
resulting from water induced corrosion (waste water).
Recommendations Proceed for re-use of existing pipe flange onto the new pipe length
CM
12"-PTW-11200-LS1 line leakage
HOT WORK
VISUAL
To cut out, remove and install new length (1 length)
DPT
PT: No indication of weld defect for the replaced length. Existing pipe
Findings length observed of biological induced corrosion effect from service
fluid condition
Recommendations Proceed for pipe length replacement work
CM
3/4"FTW handwheel found broken
HOT WORK
VISUAL
To cut out and replace valve - 3/4"(1no.)
DPT
PT: No indication of weld defect for the replaced valve. Handwheel
Findings
broken from human factor.
36
DATE:

Tag
Recommendations Proceed for replacement with new valve made
CM
Steam trap passing at Boiler A
HOT WORK
VISUAL
To cut out, remove and install new steam trap
DPT
PT: No indication of weld defect to be noted. Most probably
Findings
deterioration of internal part of removed steam trap made.
Recommendations Proceed for replacement of such steam trap valve
CM
Boiler A SH exchanger outlet steam trap passing
HOT WORK
VISUAL
To cut out, remove and install new steam trap
DPT
PT: No indication of weld defect to be noted. Most probably
Findings
deterioration of internal part of removed steam trap made.
Recommendations Proceed for replacement of such steam trap valve
CM
Drain spool broke at Boiler A
HOT WORK
VISUAL
To cut out, remove and install new length
DPT
PT: No indication of weld defect to be noted. Damaged spool length

Findings
cause unknown and yet to verify at
Recommendations Proceed with replacement of spool length
CM
Sampling line valve passing at Boiler B
HOT WORK
VISUAL
To cut out and replace defective valves - 1/2(2nos.) & 3/4"(1no.)
DPT
Findings No spare valve available for replacement works
Recommendations Propose deferment to STA 2023 due to no spare valve
CM
STG SM block valve jammed
HOT WORK
37
DATE:

Tag
VISUAL
To cut out and replace valve - 1 1/2"(1no.)
DPT
PT: No indication of weld defect to be noted. Valve jammed resulting
Findings
from stem in sticking position
CM
Vent Valve passing: SM Inlet to P-1620A
HOT WORK
DPT 3/4"(1no)
PT: No indication of weld defect to be noted. Deteriorated valve
Findings
seating to be anticipated for the removed valve.
CM
Drain valve passing: SM Header drain near to EDG Station
HOT WORK
DPT 3/4"(1no)
PT: No indication of weld defect to be noted. Deteriorated valve
Findings
seating to be anticipated for the removed valve.
CM
Drain valve passing: P-1516 discharge drain
HOT WORK
DPT 3/4"(1no)
PT: No indication of weld defect to be noted. Existing valve unable to
Findings be fully closed possibly from presence of deposit restricting such
closure be made
CM
P-1503A vent valve handle broken
HOT WORK
VISUAL
Cut, removal and replace valve - 3/4"(1no)
DPT
PT: No indication of weld defect to be noted. Existing valve handle
Findings
result from human factor
38
DATE:

Tag
CM
Valve jammed for FX-1510A
HOT WORK
DPT 1"(2nos) & 1.5"(2nos)
PT: No indication of weld defect to be noted. Valve jammed unknown,
Findings
yet to be verify.
CM
E-1205 blow down valve passing (R77, R78 & R79)
HOT WORK
DPT 2" 1500#(3nos.)
PT: No indication of weld defect to be noted. Valve passing may be a
Findings result of stem unable to fully closed due to foreign particle presence
on the stem seating area (similar to previous replacement)
CM
WHB 2"vent valve passing west side of WHB
HOT WORK
VISUAL Unbolt and disconnect piping, cut out existing valve and replacement
DPT with new - 2" 1500#(1no)
PT: No indication of weld defect to be noted. Existing valve potentially
Findings
deteriorated of valve stem condition during in service
Recommendations Proceed with such valve replacement works
Corrosion Maintenance.
Tag Scope: Maintenance & Inspection Description

39
DATE:
Corrosion Maintenance - Backlog

PR-12 AFC Structure: Bay H-K
VISUAL Surface cleaning and painting work on handrail, installation of L-
bracket, removal and replacement of bracing, bolts, and nut.
Finding Deteriorated and severely corroded structure carried out of corrosion
maintenance work, and on replacement of structural beam and bolt
fitting where applicable.
Recommendations Replacement and corrosion maintenance carried out as much as
possible for the affected zone area.
PR-12 AFC Structure: Bay K-L & L-M
bracket, removal and replacement of bracing, bolts and nut.
PR-12 AFC Structure: Bay Q-P
bracket, removal and replacement of bracing, bolts and nut.
K-1101T-E3 NG Booster Turbine Gland Leakage Condenser
VISUAL Surface cleaning and painting works
Finding Deteriorated surface paint coating along with surface corrosion
observed. Perform removal of paint flaking and carry out corrosion
maintenance along with paint re-application works.
Recommendations Corrosion maintenance and re-painting work done
K-1301T-E3 Syn Gas Turbine Gland Leakage Condenser
Finding Deteriorated surface paint coating along with surface corrosion
observed. Perform removal of paint flaking and carry out corrosion
maintenance along with paint re-application works.
E-1304 Syn Gas 2nd Stage Water Cooler
VISUAL Insulation removal, surface cleaning and painting works
Finding Surface paint degradation and corrosion effect to be noted. Perform
surface buffering along with paint re-application works
P-1621AT-E3 HP BFW Pump Turbine Gland Leakage Condenser
Finding Surface paint degradation and corrosion effect to be noted. Perform
surface buffering along with paint re-application works
Tag Scope: Maintenance & Inspection Description

Corrosion Maintenance - Backlog
FV-1121 Control Valve
40
DATE:

Finding Surface of valve and piping observed severely corroded and paint
deterioration, leading to surface bare metal surface corroded
condition.
Recommendations Carried out corrosion maintenance work and done
PV-16206B Control Valve
Finding Surface of valve and piping observed severely corroded and paint
deterioration, leading to surface bare metal surface corroded
condition.
Recommendations Carried out corrosion maintenance work and done
2.2.3 Pressure Relief Valve.

41
DATE:
For pressure relief valves the following inspection activities were carried out.
VISUAL & Inspection of relief valves at 'as-received' condition prior work bench
TEST testing (workshop)
VISUAL & Inspection of relief valves at 'as-acceptance" condition prior to
TEST dispatch back to site
Supervising, coordinating, managing, and providing quality control
QA/QC roles on relief valve transportation, testing, installation, and
overhauling works at appointed workshop

Tag
Pressure Relief Valves
PSV-1302B PRESSURE RELIEF VALVE - Direct Replacement Works
Findings Replaced.
Recommendations No recommendations.
Findings Replaced.
Findings Replaced.
Findings Replaced.
Findings Replaced.
42
DATE:

Tag
PSV-1203 PRESSURE RELIEF VALVE - Overhauling Works
Findings  Spindle thread minor corrosion
 Overhauled.
Recommendations Post pop test, back seat test and bubble test were found satisfactory
according to ASME BPVC VIII.1-2017
 Overhauled.
Findings General condition observed in satisfactory condition
 Overhauled.
PSV-1301A PRESSURE RELIEF VALVE - Overhauling Works
Findings  General condition observed in satisfactory condition
 Overhauled.
PSV-1301B PRESSURE RELIEF VALVE - Overhauling Works
 Overhauled.
PSV-1304C PRESSURE RELIEF VALVE - Overhauling Works
General condition observed in satisfactory condition

Findings Note: DPT inspection not performed due to time constraint by
workshop in reinstating the valve without undergoing for inspection
43
DATE:

Tag
 Overhauled.
 Overhauled.
Findings  General condition observed in satisfactory condition
 Overhauled.
 Pitting corrosion on Guide bottom part.

Findings  Spindle found minor corrosion as well as threading
 Overhauled.
Findings  Spindle observed of thread minor corrosion
 Overhauled.
Findings Spindle observed of thread minor corrosion
 Overhauled.
PSV-1610A PRESSURE RELIEF VALVE - Overhauling Works
44
DATE:

Tag
 Overhauled.
 Overhauled.
 Surface of inlet flange and bolt observed of corrosion

Findings  Guide with minor corrosion, including the bottom part
 Spindle thread minor corrosion
 Overhauled.
PSV-P1621AT-1 PRESSURE RELIEF VALVE - Overhauling Works
 Unable to perform inspection due to time constraint in

Findings
reinstating back of the valve
 Overhauled.
 Nozzle attachment exterior corrosion

Findings
 Overhauled.
Findings  Spidle thread minor corrosion
 Overhauled.
45
DATE:

Tag
 Overhauled.
 Nozzle attachment externally corrosion

Findings
 Spindle thread corrosion
 Overhauled.

Findings
 Spindle thread corrosion
 Overhauled.

Findings
 Spindle thread corrosion.
 Overhauled.
Findings  Nozzle attachment mechanical damaged.
 Overhauled.
Recommendations  Post pop test, back seat test and bubble test were found
satisfactory according to ASME BPVC VIII.1-2017
 Nozzle attachment externally observed of corrosion

Findings
 Overhauled.
 Nozzle attachment minor corrosion

Findings
46
DATE:

Tag
 Overhauled.
PSV-C1621-1 PRESSURE RELIEF VALVE - Overhauling Works
Findings  General condition of satisfactory
 Overhauled.
 Overhauled.
 Overhauled.
PSV-P1621A-1 PRESSURE RELIEF VALVE - Overhauling Works
 Nozzle attachment observed corrosion

 Internal part corroded.
Findings
Note: DPT inspection not performed due to time constraint by
workshop in reinstating the valve without undergoing for inspection
 Overhauled.
PSV-P1621B-1 PRESSURE RELIEF VALVE - Overhauling Works
 Unable to perform inspection due to time constraint in

reinstating works
Findings  DPT inspection not performed due to time constraint by
workshop in reinstating the valve without undergoing for
inspection
 Overhauled.
47
DATE:
2.2.4 Mechanical Rotating.

Tag
Mechanical Rotating
E-1208 RG AIR COOLER (AFC)
Minor maintenance of AFC. AFC units as per below.

 E-1208-1-1 (Pulley replacement)
Visual
 E-1208-2-1
 Found severe pitting corrosion at E-1208-1-1 and E-1208-2-
2 pulley.
 No major findings on the belt and motor conditions.
 Stud bolts and nuts conditions at guard frame, foundations,
Findings bearing housings and duct wall structure in poor conditions.
Replacement has been done at the foundation but none at
others due to unavailable spare parts.
 Tensioning bolt for alignment in poor conditions. No spare
available for replacement.
 Pulley replacement has been done on E-1208-1-1 and E-
1208-2-2.
 Due to time constrains and unavailable spare parts,
Recommendations
recommend for the replacement on stud bolts and nuts
along with tensioning bolts during maintenance opportunity
or next scheduled turnaround
E-1303 SYN GAS 2ND STAGE AIR COOLER (AFC)

Visual
 E-1303-2
 Found severe pitting corrosion at pulley.
 Minor defect on grease tube which cause grease leakage.
 No major findings on belt and motor conditions.
 Replacement of grease tube.
Recommendations recommend for the replacement on the pulley along with
stud bolts and nuts and tensioning bolts during maintenance
opportunity or next scheduled turnaround.
E-1403A METHANOL AIR COOLER (AFC)

Visual  E-1403A-1-1
 E-1403A-1-2 (Pulley replacement)
48
DATE:

Tag
Mechanical Rotating
 Severe pitting corrosion at E-1403A-1-2

 No major findings on the belt whilst motor at E-1403A-1-2 in
poor conditions.
 E-1403A-1-2 tight rod for ducting structure broke.
Findings  Stud bolts and nuts conditions at guard frame, foundations,
bearing housings and duct wall structure in poor conditions.
Pictures Broken tight rod of ducting structure.
 Pulley replacement has been done on E-1403A-1-2

Recommendations recommend for the replacement on stud bolts and nuts
or next scheduled turnaround.
E-1403B METHANOL AIR COOLER (AFC)

 E-1403B-1-2
Visual
 E-1403B-2-1
 E-1403B-2-2 (Pulley replacement)
 Found severe pitting corrosion at pulley at E-1403B-2-2
 Minor defect on grease tube which cause grease leakage.
 No major findings on belt on and motor conditions except at
E-1403B-2-2 has poor conditions on its motor.
Findings  Stud bolts and nuts conditions at guard frame, foundations,
 Pulley replacement has been done on E-1403B-2-2.
Recommendations recommend for the replacement on stud bolts and nuts
E-1503 TOPPING COLUMN NO.1 CONDENSER (AFC)
Visual Major and minor maintenance of AFC. AFC units as per below.
49
DATE:

Tag
Mechanical Rotating
 E-1503-1-2 (Actuator and bearing replacement)

 E-1503-1-3 (Actuator and bearing replacement)
 E-1503-2-1
AFC Major Maintenances
 No major findings during actuator and bearing replacement.
 Measurement checks on blade angle and tip clearance are
adjusted within tolerances.
AFC Minor Maintenances

 Found mild pitting corrosion at pulley for all AFC units
Findings
 No major findings on belt but motor in poor conditions.
 Actuator and bearing replacement completed at E-1503-1-2
and E-1503-1-3. Test run completed and satisfactory results.
 Pulley replacement has been done on E-1503-2-2
Recommendations  Due to time constrains and unavailable spare parts,
E-1512 LP REFINING COLUMN NO.1 CONDENSER (AFC)

 E-1512-5-2
 E-1512-6-3
Visual  E-1512-7-1 (Pulley replacement)
 E-1512-7-3
 E-1512-8-1
 E-1512-8-2
 E-1512-8-3
 Found severe pitting corrosion at pulley at E-1512-5-3, E-
1512-7-1, E-1512-7-2 and E-1512-8-2.
 Motor fan broke at E-1512-5-2 and E-1512-5-3.
 Pulley replacement has been done on E-1512-5-3, E-1512-
Recommendations
7-1 and E-1512-7-2. No replacement been done at E-1512-
50
DATE:

Tag
Mechanical Rotating
8-2 due to limited spare pulley.
B-1620B-K1 AUX. BOILER B FDF FAN
Inspection on the bearings conditions / Inspection on radial and axial

Visual play on fan end shaft / Inspection on clutch and trip mechanism /
Replenish Turbine Bearing Oil / Alignment check / Reinstatement /
Insulation / Lube Oil Sample Collection
 Bearing conditions matched with the findings from the previous
STA2021 where wiping mark observed both DE and NDE west
side on its top half.
 Water ingress on the clutch also observed during this SOM2022
which match the findings from previous STA2021.
Findings
 Crack on trip mechanism was observed which likely due to over
pressure during braking.
 The coupling roofing found in contact with fan bearing labyrinth
and produce new mild rubbing scratch marks on it.
 Severe corrosion found on the internal parts of fan ducting.
 Water ingress observed after dismantle

Pictures
clutch
 Replacement on fan bearings and bearing housing along with

labyrinth seal completed.
 Pin hole and corroded air duct wall was patched up due to
severe corrosion on the pipe structure.
Recommendations  Recommend installing roofing along turbine and clutch side to
minimize the water ingress issues which contaminate the lube
oil.
 Recommend putting clutch in service for observation run despite
clutch functioning well and in normal conditions.
T-1611-K1A COOLING TOWER FAN A
Visual Inspection on speed reducer gearbox and fan blade conditions /

General cleaning / Lube oil replacement / Lube oil sample collection
Findings  CT Gearbox body and foundation base corrosion
propagating
 Fan blades hub fasteners bolts and nuts corroded and in
poor conditions - Spare parts unavailable.
 Fan stack wall accumulated with algae.
51
DATE:

Tag
Mechanical Rotating
 Lifting eyebolt lugs in bad conditions - Spare parts

unavailable.
 Mild scratch at fan trailing edge and tip cap bending - Spare
parts unavailable.
 No major findings on gear patters / Normal conditions.
 Membrane (flexible element) in poor conditions - Spare parts
unavailable.
 Oil gear reducer to be change after 6 months running.
 Touch up painting was done for temporary corrosion
maintenance on speed reducer body and frame foundation.
Recommendations
 Due to time constrains and unavailable spare parts, the
remaining findings to be tackle during maintenance
T-1611-K1B COOLING TOWER FAN B
Inspection on speed reducer gearbox and fan blade conditions /

Visual
General cleaning / Lube oil replacement / Lube oil sample
collection / Speed reducer gearbox replacement
 CT Gearbox body and foundation base corrosion
propagating
poor conditions – Spare parts unavailable.
 Lifting eyebolt lugs in bad conditions – Spare parts
unavailable.
Findings
 Mild scratch at fan blade tip and tip cap bending – Spare
parts unavailable
 Severe pitting and break off at bevel pinion tooth.
 Loose and damaged expansion bolts found outside cell B
ducting base.
unavailable.
 Severe pitting and break off at bevel

Pictures
pinion tooth
 Speed reducer gearbox has been replaced accordingly with

the spare. The existing to be sent out for refurbishment.
 Oil gear reducer to be change after 500hours running from
Recommendations initial start-up.
52
DATE:

Tag
Mechanical Rotating
T-1611-K1C COOLING TOWER FAN C

propagating and may generate soft foot
 Bad corrosion at stud bolts blade blocks - Spare parts
unavailable.
 Missing one side of jacking bolt for alignment - Spare parts
Findings unavailable.
 Vibration proximeter detached on gearbox.
unavailable.
unavailable.
Recommendations
T-1611-K1D COOLING TOWER FAN D

unavailable.
Findings  Vibration proximeter detached on gearbox.
unavailable.
unavailable.
Recommendations  Oil gear reducer to be change after 6 months running.
53
DATE:

Tag
Mechanical Rotating
T-1611-K1E COOLING TOWER FAN E

unavailable.
 Alignment jacking bolt in bad conditions - Spare parts
Findings unavailable.
 Vibration proximeter detached on gearbox.
unavailable.
unavailable.
Recommendations
P-1621A-V1 HP/MP BFW PUMP OIL TANK
Visual Minor maintenance and inspection at tank, strainer and oil filter
including oil sample collection for analysis.
No major findings during external and internal inspection on tank,
Findings
strainer, and oil filter conditions.
Collected lube oil sample to be send for analysis to ensure oil free
Recommendations
from contamination.
P-1621B-V1 HP/MP BFW PUMP OIL TANK
Minor maintenance and inspection at tank, strainer and oil filter

Visual
including oil sample collection for analysis.
No major findings during external and internal inspection on tank,
Findings
strainer, and oil filter conditions.
Collected lube oil sample to be send for analysis to ensure oil free
Recommendations
from contamination.
54
DATE:
2.2.5 Instrumentation.

Tag
Instrumentation
DCS DCS – Online Parameter Change
Scope Performed Online parameter change.
Findings No abnormal finding.
Recommendations No recommendation for next STA.
DCS DCS – EDCS
Scope Implementation for enhanced Distillation Control System
Unable to completed for all function during plant start-up due to plant
Recommendations shut down.
Will be carried out remaining function during STA2023 start-up.
HV-16252B B-1620A STEAM OUTLET MOV VALVE
Scope Actuator maintenance
LEAK Test Not applicable.
FUNCTIONAL Conduct function test after actuator replaced and confirmed good
TEST function.
Recommendations The removed actuators will be repaired and kept as spare parts.
ON-OFF VALVE
HV-1205
RG TO E-1222 BY-PASS_HV-1205 - Overhauling Works
Scope Body and actuator leak test
LEAK TEST Leak Test at workshop
55
DATE:

Tag
Instrumentation
FUNCTIONAL
Installation and Functional Test at plant site
TEST
Findings Confirmed no leakage for body and actuator.
ON-OFF VALVE
HV-1204
RG TO E-1222 SHELL_HV-1204 - Overhauling Works
Scope Body and actuator leak test.
FUNCTIONAL
TEST
Confirmed no leakage for body and actuator.
Findings
Replaced booster relay due to air leakage.
ON-OFF VALVE
HV-1209
RG TO E-1223 - Overhauling Works
Scope Body and actuator leak test.
FUNCTIONAL
TEST
Confirmed no leakage for body and actuator.
Findings
Replaced speed controller due to air leakage.
ON-OFF VALVE
XV-1207
E-1223 BTM TO E-1701_XV-1207
Actuator overhaul
Scope
Actuator top cover replacement due to deformation
FUNCTIONAL
TEST
Findings No abnormal finding
56
DATE:

Tag
Instrumentation
CONTROL VALVE
HV-17001
SM TO FLARE STACK_HV-17001 - Direct Replacement Works
Scope Body replacement due to seat leakage
LEAK TEST Not applicable
FUNCTIONAL
TEST
CONTROL VALVE
LV-1510
LP COLUMN - Overhauling Works
Scope Body overhaul due to suspect seat leak
FUNCTIONAL
TEST
Findings Confirmed no leakage for body and actuator.
Transmitter Replacement – Reformer Area (26nos.)
Scope Transmitter replacement works
FINDINGS No abnormal finding
Recommendations No recommendation for next STA
Transmitter Replacement – Compressor (38nos)
57
DATE:

Tag
Instrumentation
Transmitter Replacement – Boiler Area (36nos)
Transmitter Replacement – Demi Area (3nos)
Transmitter Replacement – Distillation Area (6nos)
Transmitter Replacement – Synthesis Area (5nos)
U-1700 WWT LCP – Loop Controller Maintenance (3nos.)
58
DATE:

Tag
Instrumentation
Scope Replacement for single loop controller due to deterioration
Turbine Trip SOV Maintenance (9nos)
Scope Solenoid valve replacement works
TTV – Limit Switch Replacement (12nos)
VISUAL Limit switch replacement works
B-1620A Boiler A Instrumentation
1. PLC and touch panel replacement

Scope 2. Venturi nozzle and pipe cleaning
3. Air damper actuator replacement
Confirmed heavy corroded for the air damper and flow rate is not
FINDINGS
stable when damper is closed.
Recommendations Should consider replacing or repair for the damper.
B-1620B Boiler B Instrumentation
1. PLC and touch panel replacement

Scope 2. Venturi nozzle and pipe cleaning
3. Air damper actuator replacement
59
DATE:

Tag
Instrumentation
2.2.6 Electrical.

Tag
Electrical
K-1201M IDF Motor
VISUAL General maintenance (minor scope)
Finding Minor Soundproof cover corroded
Recommendations To replace with new or fabricate
K-1202M FDF Motor
VISUAL General maintenance (minor scope)
Finding Minor Soundproof cover corroded
P-1611AM Cooling Tower Pump Motor A
VISUAL General maintenance (minor scope) inclusive on repair for
soundproof cover
Finding Soundproof cover badly corroded
P-1611BM Cooling Tower Pump Motor B
soundproof cover
P-1611CM Cooling Tower Pump Motor C
soundproof cover
Tag
Electrical
B-1620A-K1M Boiler A FDF Motor
VISUAL General maintenance
Finding No findings
Recommendations No recommendation
B-1620B-K1M Boiler B FDF Motor
Finding No findings
UPS UPS-BT-240V
Finding Earth relay faulty
Recommendations To replace next STA2023
P-1901AM Fire Water Pump Motor
VISUAL General maintenance and fan blade replacement
60
DATE:
Finding No findings
2.3 Post STA and Start-Up Stages.
No additional inspection activities were required during the post-STA stage.

Plant start-up commenced on 03 rd October however, upon reaching 65%
Reformer load on 08th October trouble occur at K-1301T Dry Gas Seal, due
to reported of primary vent (DE) HH alarm. Troubleshooting and rectification
work are ongoing with facilitation and supervision from AST Turbo AG
(under MHIAP dispatch).
2.4 Concerns and Highlights.
61
DATE:
At time of plant initial startup, issue on set pressure setting for both PSV-
C1621-1 and PSC-C1621-2 encountered whereby the post-SOM set
pressure were set at lower value compared to design, result in low pH feed
onto BFW service fluid for 2 days. Temporary corrective action taken on the
spot in resetting such set pressure back to design manually.
At current plant shut down resulting from K-1301T issue, no major concern
to be highlighted at.
2.5 Recommendations.
On the PSV issue, lack of proper supervision by focal point at PSV

workshop lead to such incorrect set pressure being set. Iy is necessary to
review on such finding, and to consider for proper instruction be issue in
ensuring future management o PSV workshop overhauling are consider to
prevent recurrence of similar event occur.
3. Cost
3.1 Original Cost.
Service Contractor WO USD

NDT IRS A2203004/TED 111,930.66
QA/QC PTAS 6009681 25,784.67
E-1205 NDT PTAS 6009560 66,500.16
E-1206 PWHT IRS 0.00
TOTAL USD 204,215.49
Note: COVID cost is not applicable for all above services
3.2 Cost Variance.
Contracto Original Cost

Service Final Cost %
r Cost Variance
NDT IRS 111,930.66 0.00 111,930.66 0.00%
QA/QC PTAS 25,784.67 - 2,645.99 23,138.69 -10.26%
E-1205 PTAS
66,500.16 30,049.59 96,549.75 45.19%
NDT
E-1206
IRS 0.00 39,372.59 39,372.59 100.00%
PWHT
TOTAL USD 204,215.49 66,775.87 270,991.36 32.70%
62
DATE:
Cost variance was a consequence of delays in site preparation for inspection,

clashing of work activity with nearby equipment activity that cannot be avoid (RT
inspection), lack of manpower and coordination as well as the requirement for
provision of additional inspection services be required to participate on such
equipment maintenance and inspection activity.
A few additional scope of inspections made during this SOM were notably made
chargeable under the existing Annual Inspection Contract Rates (ad hoc
requisition). The detail on each of such additional scope of inspections are detail as
following.
Tag Description of
NO Change Request
Numbe Additional Origin
. Number
r Inspection
Provision of Services
in supplying manpower BFW Piping
and resources for both Fabrication Class
1 SI-IRS-001 E-1206 PWHT and Genset for requirement as per
E-1206 BFW Piping Specification
Fabrication Works on document
site
63
DATE:
Tag Description of
NO Change Request
Numbe Additional Origin
. Number
r Inspection
Request from MTD

Provision of DPT, MPI to carry out NDT
BMC_2022_ISR#001 & ECT testing services services for K-
2 K-1201T
4 for K-1201T Governor 1201T Governor
TTV Valve/Seat & Trip
Valve
Provision of PAUT and

Hardness Test
inspection services for To verify weld joints
BMC_2022_ISR#001
3 E-1206 E-1206 BFW Piping condition following
5
Fabrication Works on PWHT works
site post for PWHT
works
Pipe fitting for 2

Provision of
weld joints did not
Radiography Testing
allow for proper
services for E-1206
BMC_2022_ISR#001 probe placement for
4 E-1206 BFW Piping
6 PAUT Inspection to
Fabrication Works on
be carried out. RT to
site post for PWHT
be substituted
works
instead
Recommendation
from TPI assigned
Plant Inspector to
Provision of DPT
carry out additional
Inspection services for
BMC_2022_ISR#001 DPT Inspection for
5 V-1620 V-1620 Deaeration
7 circumferential weld
Tank Circumferential
seam close to the
Weld Seam
manhole where
linear indications
were observed
The following additional inspections could have been avoided and

considered as part of the original inspection scope:
a) Proper understanding on the scope of fabrication by Contractor under MTD

coordination, to pre-define on the necessary ITP to be incorporate as part of
64
DATE:
such fabrication works. Piping fabrication specification document to be

thoroughly review, understand, and include on the necessary NDT and
fabrication requirement be made for such piping specification.
b) For E-1205, it is recommended to include a minimal tube quantity to be firm
scope and to undertake in the SOM opportunity.
4. Schedule
4.1 Original Schedule.
Original inspection schedule was aligned with SOM 2022 L4 schedule by

Main Contractor:
Activity Start Date End Date Durations

(Days)
Plant Ramp Down/ 15th September 18th September 4
Make Safe Condition 2022 2022
Engineering Days 19th September 02nd October 2022 14
2022
Plant Startup 03rd October 2022 08th October 2022 6
Operations
Primary gas seal vent High-High alarm was detected for K-1301 HP side
during compression startup operation (65% Reformer load), leading to
further high alarm on primary gas seal vent of DE side and eventual K-
1301T tripped operation. It was decided to perform total Reformer shut
down for rectifying on the issue arose.
Plant Startup Operation was thus interrupted resulting from such failure
finding and progressive shut down occurred in finding on fault cause and
necessary rectification works.
4.2 Schedule Variance.
Original inspection scope of work including additional change orders issued

was completed 100% and within the time schedule period. Actual execution
may exceed the intended inspection duration within the equipment period;
however, such has no impact toward any direct delay cause on equipment
completion and handover perusal.
65
DATE:
It is recommended to consider on all good and bad case scenario to be

anticipate on each of the equipment for maintenance, in order to adequately
cover on all applicable NDT inspection scope to be foresee in the planning
of works.
5. Quality
5.1 Definition
Our definition of QA and QC for the SOM 2022 was:
An integrated QA/QC organization including MTD, and TED personnel

implemented.
Three additional QA/QC inspectors were contracted from a local inspection

company to support the organization.
In many cases the assigned personnel were considered to have both

maintenance execution and QA/QC roles and responsibilities.
The organization was segregated according to discipline basis.
66
DATE:
For every equipment an EEP (Equipment Execution Plan) was delivered.
Each corresponding EEP template is a guideline with relevant activities to

be checked from WA/QC point of view by the responsible positions on BMC
and/or Contractor (see Section 10.2)
Non-conformity NCR form was also delivered for those cases where there is
an identified major deviation (see Section 10.3)
For NDT Inspection Contractor and Main Contractor, a QA/QC team was
requested.
A SharePoint was delivered together with ITD to have a common

collaboration and daily reporting site easily accessible through internet from
anyplace by all involved parties.
67
DATE:
 Lack of detailed information and clarity of status of NDT inspection

activities presented by Contractor’s QA/QC Coordinator during daily
meeting
 Lack of recommendations and acceptance criteria in Contractor’s
inspection reports even it was clearly requested in RFQ specification.
 Insufficient awareness for using EEP template (quality check and
compliance of maintenance and inspection activities)
 Lack of a daily joint discussion with concerned parties to decide and
agree on remedial actions and/or recommendations
 Non full compliance with expected dual maintenance and QA/QC
roles and responsibilities.
 Request during contracting process a minimum standard of

presentation required by BMC during STA meetings including:
 Activities completion (plan vs real)
 Daily plan
 Concerns
 Highlights
 Recommendations
 Review, improve and update inspection reporting requirement from

Contractor in future RFQ specifications
 Prepare a SOM/STA Quality Plan including EEP templates and clear
definition and resources balance of roles and responsibilities with
sufficient time before for awareness preparation of involved parties.
Minimize dual supervision/ quality roles.
 Anticipated awareness to users to get out more of the Share Space
for optimizing in utilization by all users.
 Explore the implementation of a SOM/STA technical evaluation
committee for reviewing relevant findings after inspections and agree
on recommendations daily or as required. Team an meet and discuss
after daily SOM/STA meeting
6. Contractors
6.1 Organization
68
DATE:
BMC provided engagement for following contractors
 Provision of NDT Inspection Services to execute inspection and

testing activities under IRS Sdn Bhd who undertake on equipment
inspection and integrity check for assigned equipment list.
 Provision of 3 QA/QC Inspectors manpower under PTAS-ITS Sdn
Bhd to support BMC QA/QC organization on Static equipment
maintenance
 Provision of NDT Inspection Services (to PTAS-ITS Sdn Bhd JV) to
undertake on E-1205 WHB inspection relate works. The WHB
represent a standalone item for SOM execution, utilizing the same
Maintenance Contractor for the engineering.
 Lack of detailed information and clarity of status of NDT inspection

activities presented by Contractor’s QA/QC Coordinator during daily
meeting
 Lack of recommendations and acceptance criteria in Contractor’s
inspection reports even it was clearly requested in RFQ specification.
 Request during contracting process a minimum standard of

presentation required by BMC during STA meetings including:
 Activities completion (plan vs real)
 Daily plan
 Concerns
 Highlights
 Recommendations
 Review, improve and update inspection reporting requirement from

Contractor in future RFQ specifications
 Explore the implementation of a SOM/STA technical evaluation
committee for reviewing relevant findings after inspections and agree
on recommendations daily or as required. Team and meet and
discuss after daily SOM/STA meeting
7. Management, Staffing and Organization
69
DATE:
7.1 Organizations
70
DATE:
71
DATE:
72
DATE:
8. Summary of Relevant Recommendations

 Proper tube cleaning
 Tube extubation
 Tube plugging works
1 E-1205
 IRIS inspection STA 2023
 Refractory inspection and
repair works
2 E-1206  TMT UT measurement STA 2023
3 F-1201  Outlet pigtail DPT inspection STA 2023
 Tube Sock Replacement/
4 F-1201 STA 2023
Repair works
5 F-1201  Burner VT inspection STA 2023
6 F-1201  Finger Duct VT Inspection STA 2023
 Outlet System Insulation
7 F-1201 STA 2023
Repair/ Replacement Works
 Radiant Box Structural
8 F-1201 STA 2023
Corrosion Maintenance
9 F-1201  Transfer line VT Inspection STA 2023
 EJ#14 and EJ#15
10 F-1201 STA 2023
Replacement works
 EJ#9 and EJ#16 VT
11 F-1201 STA 2023
inspection
 Refractory inspection on
Radiant box, Convection
12 F-1201 STA 2023
Module, Transition Duct and
other area of concern
TMT UT measurement and EX
13 E-1209 STA 2023
overhauling works
14 K-1201T Major maintenance STA 2023
15 K-1201T-TK1 Sampling and LO replacement STA 2023
16 K-1301-P1A Major maintenance STA 2023
17 K-1301-V1 LO Replacement STA 2023
18 K-1301-P1AT Minor maintenance STA 2023
19 V-1402 Bottom cleaning works STA 2025
20 T-1501 Cleaning and inspection STA 2023
21 G-1670T Major maintenance STA 2023
22 G-1670-Z1 Major maintenance STA 2023
23 G-1670-V1 LO Replacement STA 2023
24 U-1620-V4A Resin replacement works STA 2023
25 P-1620A Major maintenance STA 2023
26 P-1620AT Major maintenance STA 2023
27 F1740 Refractory repair works STA 2023
Agitator feed shaft and housing
28 W-1714 STA 2023
replacement works
29 TK-1901 Bottom plate repair works STA 2025
30 G-1670 General maintenance works STA 2023
31 LTR101 to 104 TR General maintenance works STA 2023
73
DATE:

32 MTR-010A/B-TR General maintenance works STA 2023
33 HSWY-100A/B General maintenance works STA 2023
34 SC-100A/B General maintenance works STA 2023
37 LMCC-101 to 106 General maintenance works STA 2023
38 TDG General maintenance works STA 2023
39 Probe Maintenance Calibration works STA 2023
40 FT-18001 Direct replacement works STA 2023
Additional O2 Analyzer
41 QT-1207-2 STA 2023
installation
UT Thickness Measurement
according to RBI Plan
Data from SOM 2022 will be
analyzed according to nominal
thickness, corrosion rates and
remaining life estimations, for
According to RBI
42 delivering recommendations
Plan
and update/ confirm RBI
program schedule.
Outstanding from SOM 2022 that STA 2023
were unable to be performed
of UT measurement to defer
for STA execution
9. Lessons Learnt
74
DATE:
Aspect Issue Lesson Learnt
Planning Equipment listing not The defined listing are not taking into consideration on
Stage properly defined for previous recommendations, such need to be review
execution thoroughly in order to optimize on opportunity for
execution
Planning Scope for maintenance Change of scope are within MTD, and not properly
Stage change without cascade to SOM members. It is important to provide
awareness such cascading time to time to ensure all updates are
as per latest edition
Planning Cancellation of scope Weekly meeting shall be used to highlight on any issue
Stage not mutually agree at of concern, and way forward/ decision on proceeding,
instead of only between selected personnel
Planning Lack of proper Lack of follow up and communicating between
Stage coordination and department to ensure smooth preparation are in place.
communication MTD need to provide such communication time to time
with all department involve
Pre-SOM Lack in follow up on Discipline focal point shall take lead in coordinating with
Stage Contractor preparation Contractor in ensuring all preparation are adequate,
instead on relying on MTP for the overall scope.
Pre-SOM Lack understanding on Both BMC and Contractor lack the content and
Stage work pack scope understanding on work pack scope, require re-
educating BMC internal, and get the right person for the
right job for contractor side
Pre-SOM Internal inadequacy for Spare part list unable to be define due to lack of
Stage spare part preparation responsibility by focal person. Instruction need to be
made to all for mutual understanding and commitment
SOM Stage Poor resource planning Lack of resources by Contractor will require to be re-
by Contractor assess in ensuring all resources are well ahead plan
and in place prior to SOM execution
SOM Stage Poor understanding of Contractor supervisor do not have experience and
Contractor in knowledge on equipment scope. Assessment on
undertaking on supervisory level require to be made in advance, prior
maintenance works to undertake on the scope.
Cost Cost variance: a. PWHT services was overlooked, and
a. Cost variance by fabrication requirement shall be thoroughly
IRS review to incoporate on any other services be
b. Cost variance by require in future exection
PTAS b. IRIS inspection that are conducted at
opportunity will require to be kept as firmed
scope of % application in future engagement
Schedule a. Insulation a. Lack of resources and understanding can be
removal works minimized with a better coordination
b. Scaffolding b. Lack of resources and understanding can be
erection minimized with a better coordination
c. Delays in c. Lack of permit awareness on requirement, poor
maintenance setup of site preparation and lack for
commencement management in coordination need to be re-
of works look.
NDT Lack of detailed Request during contracting process a minimum
Inspection information and clarity of standard of prepsentation reqired by BMC during SOM
75
DATE:
Aspect Issue Lesson Learnt
Contractor status of NDT inspection meetings including:

activities presented by  Activities completion (plan vs actual)
Contractor’s QA/QC  Daily plan
Coordinator during daily  Concerns
meeting  Highlights
 Recommendations
NDT Lack of Review, improve and update inspection reporting
Inspection recommendations and requirement from Contractor in future RFQ
Contractor acceptance criteria in specifications. Include acceptance criteria such as
Contractor’s inspection minimum required wall thickness value
reports even it was
clearly requested in RFQ
specification
Management Lack of assigned To retain assigned personnel be full time for the
, personnel availability duration and not allow for offsite relate activity outside
Staffing and due to other of BMC scope
Organization commitments
Management IRS QAQC Coordinator In future enagement to review on past experience in

, require to understand on undertaking as coordinator role management, in order
Staffing and shutdown management to have the right person with right experience for the
Organization for site execution undertaking.
Management Late submission and To enable advanced/ early engagement and to provide
, approval of require firm allocation of assigned personnel at least 1 mnth in
Staffing and documentations owing to advance without any inerruption of planning
Organization constant change of
resources
10. Annexes
10.1 Final Inspection Reports.
SOM-2022 final inspection reports are available in the BMC Share Point
TED & MTD Search Engine.
76
DATE:
10.2 Equipment Execution Plan (EEP) Example Template
77
DATE:
10.3 Non-Conformity Report (NCR) Template
78
DATE:
10.4 Photographic Report – Static Equipment (Relevant)
79
DATE:
10.5 Photographic Report – Rotating Equipment (Relevant)
80
DATE:
81
DATE:
82
DATE:
10.6 Photographic Report – Instrumentation (Relevant)
10.7 Photographic Report – Refractory (Relevant)
83

221105A-01AF-TED SOM-2022 Final Report

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221105A-01AF-TED SOM-2022 Final Report

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BMC BRUNEI METHANOL COMPANY

TED FINAL REPORT REV 0

TED Final Report

TED FINAL REPORT REV 0

Technical Department Final Report

7. Management, Staffing and Organization

TED FINAL REPORT REV 0

This report describes the results of the non-destructive inspection activities

The purpose of the inspection activities during the operational opportunity

Inspection and quality activities comprised equipment and systems of all

The team identified several issues resulting in immediate remedial actions

Following areas of good performance were noted:

 Accurate daily reporting of findings.

The most significant issues identified were:

 F-1201 Reformer’s Burners: recurrency of damage in every

TED FINAL REPORT REV 0

 SharePoint site not effectively used.

The relevant recommendations are:

Item Equipment Recommended Action Timeline

TED FINAL REPORT REV 0

Item Equipment Recommended Action Timeline

The QA/QC management team express their commitment to address the

2.1 Planning and Pre-SOM Stages.

Scope of technical department activities was selected through a risk

Timeline was selected based on non-availability of natural gas from the

TED FINAL REPORT REV 0

Plant Start-up Operations

Technical department was requested to be responsible of the following

 Static equipment external and internal visual inspections during pre-

During this stage TED supported:

 L4 schedule update for inspection activities.

TED FINAL REPORT REV 0

 Assignment of QA/QC roles and responsibilities for TED/MTD staff.

 NDT Services: Industrial Reliability Services, IRS

Mobilization of contractors started before September 15 th, 2022, for

2.2 STA Stage.

2.2.1 Process Engineering.

No activity related to process engineering were planned or executed in

2.2.2 Mechanical Static & Piping.

Static Equipment and Piping.

Tag Scope: Maintenance & Inspection Description Mechanical Static

TED FINAL REPORT REV 0

Tag Scope: Maintenance & Inspection Description Mechanical Static

TED FINAL REPORT REV 0

Tag Scope: Maintenance & Inspection Description Mechanical Static

Tag Scope: Maintenance & Inspection Description Mechanical Static

TED FINAL REPORT REV 0

Tag Scope: Maintenance & Inspection Description Mechanical Static

TED FINAL REPORT REV 0

Tag Scope: Maintenance & Inspection Description Mechanical Static

TED FINAL REPORT REV 0

Tag Scope: Maintenance & Inspection Description Mechanical Static

TED FINAL REPORT REV 0

Tag Scope: Maintenance & Inspection Description Mechanical Static

TED FINAL REPORT REV 0

Tag Scope: Maintenance & Inspection Description Mechanical Static

TED FINAL REPORT REV 0

Tag Scope: Maintenance & Inspection Description Mechanical Static

TED FINAL REPORT REV 0

Tag Scope: Maintenance & Inspection Description Mechanical Static

TED FINAL REPORT REV 0

Tag Scope: Maintenance & Inspection Description Mechanical Static